When we first brought the khaki TJ home I put the Jeep up on jack stands and did a lot of fixing and maintenance. I'm not going to go into depth of everything I had to do, unless somebody has a specific question, but let's just say that the shop in Oregon left about a months worth of work for me to do and I'm still finding stuff. As part of that, I changed every fluid to establish a record of when it was last serviced.
One thing that I like to do every oil change is look over the Jeep front to back while the oil is draining. I look it over as if I'm inspecting a car to buy, even if I just fixed something I treat it as the first time I've seen it. This allows me to identify any problems. Some of them are a 1 minute fixes and others require parts to be ordered. This Jeep is also Mrs. Tox's daily driver and I have a full time job. So taking all of that into account I prioritize in what order the issues need to be taken care of.
Here's what I noticed the last oil change:
The brake master cylinder is weeping. I'm not really sure where it's leaking from. The area around the cap is dry so I suspect the tank seam might be cracked. I wiped it off but it got wet again after a few days. Because brake fluid is hygroscopic (meaning it attracts and absorbs water from the air) this is a high priority item to fix before the brake lines rust internally. I'm pretty sure I have a new one on the shelf already that I can use.
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The grease fitting on the trackbar sheared off at some point. It's not high priority since I can still grease the joint.
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At some point somebody replaced the OEM stainless steel torx screws for the headlight bezels with steel phillips and they're starting to rust. I'm going to see if I can buy some OEM screws for a reasonable price. It's not high priority but I would like to do this before the rust bleeds and discolors the plastic bezel.
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The automatic switch in the underhood light doesn't turn on more than it does turn on when the hood is open. These switches are known for being troublesome. Since cell phones all have flash lights built in these days this isn't an urgent fix but it always bothers me when something that should be working doesn't. You can also see where the brake fluid splashed slightly on the hood.
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I don't have a picture of it, but there's also a leak between the Rubicrawler and the 42RLE transmission. I'm not surprised since literally everything else the shop touched leaked and I've already fixed 4-5 other leaks under the Jeep. A good size puddle of ATF always drips under the Jeep at night and leaks about a quart every 6 months. I'd like to prioritize this high before I forget to top off the ATF, and I hate any leaks, but due to the time involved to fix and higher priorities I'm not sure I'll get to it during this round of fixes.
One thing I've been aware of for about a year now is that it seems somebody used leak stop in the cooling system and it's coming apart as flakes in the coolant. I flushed it last summer putting about 20 gallons through it along with chemicals and the heater core started leaking (maybe what they were trying to fix originally?). I've also noticed coolant drips out of the AC drain and can be smelled inside when the Jeep gets to temp. This is going to be a larger project to fix and I'd like to get it done soon before we start seeing freezing temps at night. Before replacing the heater core I'm flushing the system again to get all of the flakes of leak stop out.
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Last winter the HVAC fan stopped working sporadically and I narrowed it down to a fried electrical connector that isn't seating well. If anyone is parting out a TJ I'd be interested in buying this connector and the headlight bezel screws from you.
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We removed the doors for some summer fun and when putting the passenger door back on the factory insert folded inside the hinge. I already replaced the bad ones with Delrin inserts, but still need to get around to replacing the driver's side inserts.
The mid-arm JohnnyJoints are very stiff to the point that one of the jam nuts actually came loose. They were previously blasted with a high pressure grease gun and I wouldn't be surprised if some of the bushing are distorted. I'm going to open all of them up for inspection and a fresh coat of grease. I have a couple of bushings on order in case I need to replace them. This is going to be a high priority to get done before damage occurs.