WVJeep304's never-ending 2002 TJ build

WVJeep304

TJ Enthusiast
Original poster
Supporting Member
Joined
Sep 21, 2023
Messages
587
Location
WV
I've lurked here since before I bought my TJ almost 3 years ago and only recently made an account. I decided it was finally time to introduce myself and my 2002 TJ.

After wanting a TJ for many years, I finally found a great deal on a solid Jeep back in March of 2021. We already have a black JKU, and I've had 3 other black vehicles in the past that all made me swear I'd never own another, but for the price and condition of this TJ, I couldn't pass it up. I bought it from the second owner, who purchased it from his neighbor. The only reason for selling was because his wife told him it was time to get rid of some of his 13 vehicles. He'd barely even put any miles on this one since he owned it. The hard top had never been off, the Jeep had never been offroaded, and it is a 4.0 5spd that had only 103k miles. The best part, I got the price down to $7500, which is ridiculously cheap in my area. Here's what she looked like the day I brought her home--faded top and all.

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So as soon as I got it home, I started making a to-do list. Since I don't have a lift in my garage, I decided it best to just take it to my buddy's shop and do the work there. We went through EVERYTHING. Changed all fluids, replaced a leaky pinion seal, all new brake hardware and lines, new seals in the steering box, and searched for rust. The only rust was a couple of spots in the usual places on the tub-- passenger side rocker area below the door, and under the tire snubber on the rear directly above the bumper. Easy fixes for a later date.

So 90% of the work I did was preventative, something I do for every vehicle I buy. This Jeep was bought for fun, but also to be a daily so that I didn't have to put miles on the 3/4ton Silverado I bought 3 weeks earlier. So after around $2k worth of parts and a few hours of effort, I felt she was roadworthy.

Once home, I decided the first things I needed to handle were the anemic sound system and the faded hard top. I bought new Kickers for the soundbar and some Pioneers for the dash and paired them to a cheap single din bluetooth media player until I decide on something better. So far, at closing in on 3 years later, they've treated me well. I also built a sub box for a 10" sub I had laying around and all together they make listening to music in the TJ a pretty enjoyable experience.

As for the hard top, I cleaned it really well, degreased it, taped everything off, and then coated it with Flood Penetrol. It definitely required a little bit of time and sweat (mostly because I'm OCD and everything has to be just right) but it turned out looking better than I could have imagined. The finish still looks fantastic today.

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I spent a month or two deciding on my suspension. I knew I wanted to lift a little, but didn't want to go too high. Partially for the cost it would require for much more than 2", and also because my fiancé is 5'2" and has a hard time getting in as it is. I decided to go with 2" Pro Comp springs and RS5000x shocks. I also threw on a set of 15" Pro Comp 1061 in a polished finish and wrapped them with some 31/10.50 General Grabber A/Ts. At this point, I was pretty happy with the look. Although I figured out quickly that thanks to some driveline vibes, I would have to install a TC drop. No biggie.

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So after a few trips to Fayette County and the New River Gorge area for some exploring, eating awesome food, and general sightseeing, a stroke of bad luck hit--1.5hrs from home. The radiator puked all over the parking lot as we waited for a table at our favorite restaurant. Upon first visual inspection, I couldn't see a problem, and decided to limp it to a parts store a few blocks away for some more coolant. I made it as far as a gas station a couple blocks up the road and she started to heat up again. I pulled off, shut 'er down, and found the culprit.

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After not being able to get a wrecker, a friend and his wife pulled their trailer to us, helped us load up, and took us back home. We pulled in the driveway around midnight. Once I got the Jeep in the garage, I immediately started searching for a Mopar replacement. Summit had them in stock and had one in my hands in about 36 hours. Back on the road!

But not for long.....

I kept noticing coolant disappearing from the overflow jug. Pressure tests revealed no issues. I saw no leaks anywhere. After a couple of months of this, I finally dug deep one day. With the engine running, I looked through the oil cap while revving the engine and lo and behold-- coolant gurgling up from a crack between 3 & 4. SO.....this is where Just Empty Every Pocket comes from.

I ordered a new head from Clearwater, new rockers, pushrods, plugs, injector seals, head gasket, idler pulley, and everything else I could think of within reason. The biggest issue is this was in the height of the covid shortages. Once the head finally arrived, the Jeep had been sitting headless for a month. It took another month for the other necessary parts to arrive. To say I wasn't impressed with the quality of some of the parts would be an understatement. After all the money and waiting, I had to go through and clean up, debur, and re-drill the rocker arms because they looked like absolute trash. A couple of other miscellaneous parts had to be returned/replaced, then finally I was ready to reassemble.

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I spent the next few months doing little things here and there, including stripping the interior and giving everything a good deep clean. At some point, I finally got sick of driving around in a fishbowl and had all the windows tinted with 20%. I added some Auxbeam lights to the front bumper, removed the airbag switch and made a panel from Kydex to take its place. I ended up putting a 12v outlet and a double USB outlet in it. This is a prototype at the moment, as I wait for my sister to 3d print the final piece. I also ordered some parts and pieced together a cell phone mount and added a Kenwood TK880 programmed for GMRS. A few more adventures and several hundred miles of fun until I found myself again replacing the radiator. The Mopar replacement with less than 7k miles on it failed at the crimps for the top tank. I kept the radiator to have it re-crimped, but in the meantime I ordered and installed a Denso unit. 8k miles later and it's treated me well.


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I now decided to go ahead and grab some bumpers. I had a very specific look I was going for, and happened to catch what I wanted at a good price. Slapped them on one saturday afternoon and have been really happy with the difference they make in the appearance alone. It was about this time I also decided to go ahead and replace the windshield cowl seal. I was a bit nervous what I might find when I folded down the windshield, but was pleasantly surprised to find no rust, no issues. I installed the new seal and no longer have any water finding its way into the cab.

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So, that pretty much brings us to today. I don't, and don't plan, to do any real hard core rock bouncing or anything. My friends and I just really enjoy trail riding and some milder stuff. We run our Jeeps on some land my buddy owns that we're in the process of converting to a private shooting range and general hangout area and they've been invaluable for accessing that property and getting work done while we get the road built for less capable vehicles. I now have some BDS 3" springs awaiting install after some issues with the Pro Comp springs. I can't get around to that until I have the upper spring buckets cut off and replace/relocated as they've majorly deteriorated in the last couple of years. Once that's done, I'll move on to a new Moryde spare tire carrier & hinge reinforcement kit. A re-gear, lockers, SYE, and some other mods are in the works, but I have some decisions to make before pulling the trigger on any of those. I'll try to keep this thread updated as the TJ progresses.
 
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Welcome to the forum and nice looking Tj. You've done some nice work to it so far. Thanks for sharing.
 
Welcome to the forum and nice looking Tj. You've done some nice work to it so far. Thanks for sharing.

Thanks! This forum has helped me make several decisions already. While I haven't done anything revolutionary, hopefully as I keep this updated, there may be some info that helps others.
 
What part of WV? I'm originally from Summersville.
 
How’s the Project going??

Well, it's actually been on hold. I think I've done a few little things since starting this thread, but then got busy with work, projects around the house, and then got the chance to buy a truck from a buddy that I've tried to buy for 10 years. It sat undriven and neglected for the last 4 or 5 years, so I got a SMOKING deal on it, but that meant it also needed a lot of work. But it's a 2004 GMC Sierra regular cab Z71 with 5.3L. It has a 6" BDS lift and only had 127k miles. Sooo.... My attention has been on it since last September. Hoping to get back to the jeep upgrades in the next couple of months now that the GMC is on the road again.

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What have you done to the truck so far?? Maintenance and upkeep? What are your plans for its future?

That's a BIG list. It wouldn't even start when I towed it home. So, I got a new battery, new alternator and some fresh gas and it fired right up. Then the real work began. I replaced all of the brake hardware, brake hoses, all brake lines with stainless steel. New leaf spring bushings, new shocks, cut out rusty rocker panels and put some plastic rocker covers over until I can weld in the metal replacements. New window motor regulator, new window switch panel, new headlight switch, new foglight housings (headlight, marker light, and taillight housings up next), repaired the transfer case encoder motor, new 4wd Actuator, new shocks, new 3rd brake light, new headunit and speakers, new torsion bar drop bracket bushings, new fuel pump, new door hinge pins. I'm positive I'm forgetting some stuff, but that's what comes to mind right now. Doesn't seem like a whole lot, but some of that stuff is quite time consuming.

One of the most labor intensive parts was the clean up. I spent weeks cleaning/cutting/buffing the paint. It had tree sap, algae, and tons of unidentifiable junk all over it. It really needs a new paint job, but with the exception of the hood and roof, it turned out quite nicely. The interior looks brand spanking new and I haven't even actually deep cleaned/detailed it yet, just a quick clean up.

The plan was for my fiancé to drive it while I do some work on her jku. So far, that hasn't happened and it's replaced the TJ as my daily driver and helping me keep the miles down on my 3/4 ton truck. Soon though, she'll start driving it for a while so I can get her jeep squared away, and as long as owning this truck doesn't interfere with any other plans, I'll keep it around. It runs GREAT and is handy to have around. This is the 5th or 6th truck of this body style I've owned, and the 5.3L in it is by far the best and smoothest running. And at this point, I only have around $5k invested, so it's kind of crazy to get rid of it unless I want to double my money.
 
Pretty impressive and I’m glad to hear it’s holding up for it. Have you done any work to the motor? I love the 5.3 and was wanting to swap one into my TJ

Other than an oil change, it hasn't needed a thing. Even with 33 or 35 in tires, this thing will absolutely fly. It's my first reg cab with a 5.3L, and it was quite a shock how peppy it is. I have to ease into the throttle when I pull out to keep from smoking the tires. But the engine runs smooth and quiet, doesn't even have the typical 5.3 hesitation at idle that all from this era had.
 
Well, it's actually been on hold. I think I've done a few little things since starting this thread, but then got busy with work, projects around the house, and then got the chance to buy a truck from a buddy that I've tried to buy for 10 years. It sat undriven and neglected for the last 4 or 5 years, so I got a SMOKING deal on it, but that meant it also needed a lot of work. But it's a 2004 GMC Sierra regular cab Z71 with 5.3L. It has a 6" BDS lift and only had 127k miles. Sooo.... My attention has been on it since last September. Hoping to get back to the jeep upgrades in the next couple of months now that the GMC is on the road again.

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GMT800 peak truck 💪
 
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What donor vehicle do you recommend taking a 5.3 from??

I'd look for an LM7 (iron block, 99-07) or L33 (aluminum block, 05-?). The biggest benefit to the L33 is a little weight savings and the heads are a little better. They're a bit harder to find though. I've always been a big fan of the LM7 and they're much easier to come by.
 
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