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Part 1: Parts Cannon!! Can it be saved? 95 Jeep Wrangler 4.0
Part 2: Frustrating Diagnosis! It LIVES AGAIN! Jeep Wrangler 4.0
Customer States: Engine barely runs and has a severe lack of power. It also has the occasional no start or long cranking before it starts. So far I've found vacuum leaks, clogged ports, antifreeze leaks from the water pump and the electric fan is damaged. I had the fuel pump, filter, spark plugs, ignition wires, and a distributor cap and rotor. It also has a new coolant temp sensor, O2 sensor, MAP, intake demp, IAC and throttle position sensor replaced. The ECM / PCM has been replaced too. See part one.
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Hi everybody, welcome back! Some of you should remember this: This is a 1995 Jeep Wrangler 4-liter straight six a manual transmission. It was here earlier I Already made a video on it. The thing barely ran and couldn't get out of its own way. It was stalling, backfiring, hard starting. Uh, folks had loaded the parts Cannon and uh, it came to me in the desperate need of some. TLC It sat for a very, very long time. I think like four or five years that thing sat around. the owner's been piecing it back together, but we couldn't get it quite right. I Ended up finding that the distributor was uh, either loose inside or there was something wrong with the pickup module. I I did employ the triagnostic method and I just tossed one in there and reset timing and thing was good to go. so it's running like a top. If you missed that video, just check down below in this video's description. It will take you back in time to the part one. That being said, we are moving on. We have to do something about this. uh, this failed cooling fan right here and Uh something's going off the relay I think I I heard it keep blowing fuses. Probably because uh, that fan is hitting the water pump which is also leaking. So what we're gonna do today is pop the span out of here. I have a replacement fan around here somewhere. I've got a new Uh temperature probe module that's supposed to actuate the fan. uh, that's on the way. They didn't have that in stock so we're going to pull this fan out. We're gonna drain the coolant and I'm also going to put a new water pump on this because this pump happens to be leaking coolant everywhere and you can see uh down below. We got coolant spilled all over the floor. So we're going to go ahead and uh and get started on that. My first order of business is going to be to get this fan out of the way because it's flippy flopping. It's hitting the water pump pulley. It seems to be mounted with some bolts on this little plate right here, which I'm assuming is designed to just channel the air into the fan. I'm going to go ahead and pull this entire assembly out as one unit and then we'll try to disassemble the fan. I'll see if my new one fits. however I don't really want to use the new one because I want to put the fan the new fan I'm sorry I don't want to use the old one or this I Want to put the new fan on the front side of this radiator and have it be a pusher fan rather than a puller fan simply because of the lack of clearance right here. So we're looking at four bolts that hold this little panel in. I'm going to go ahead and extract those right now. We'll get this thing removed now if I find out that my new fan has a lower profile than this fan then I will put it back together as a polar configuration. but it's all going to have to. Uh well. it's all going to depend on how much clearance I end up with that's not coming out. Oh I Can already see why that doesn't fit because somebody used this type of Bolt on a fitting that requires a fine thread. not this, uh, wood screw looking business. All right, let's move around to this side. We've got two more bolts over here. Uh, let's see that can stay I'll probably end up just cutting these wires off actually. Uh, I'm just gonna go ahead and cut that off right now. we don't need that anymore and two more bolts. This little fan guy right here. Okay, now the fan and bracket are disconnected. Let's go ahead and extract those. Hope I can do this without pulling the uh hose off upper hose. Yep, sure can. All right fans out. Oh yeah, this thing's locked up solid. We'll check this out. It doesn't even turn. Look at that locked up solid. and that is due to those bolts hitting the shaft right here and they've deformed everything. That's what's going on. So yeah, this fan is kaput. that's the Scheissa. Oh, there we go. it's freed up. now. look at that. I fixed it all right. Job's over. See you guys later. Hello wife unit Embarrassed? Yeah yeah. I'm camera shy. All right. All right here. let's unbox. uh, our new unit. It's a Hayden manufactured fan I believe that's a brand name I've used these before Once Upon a Time Uh, it does not look like it's very low profile here. Yeah, that looks, uh, that's fairly large-ish I Dropped some goodies. might need those later. That's the mounting kit. Come here. This is a 16 inch fan that should be sufficient. Uh, for what we need. Okay, this is the same diameter as the unit that's coming out. I'm wondering if I can mount this to that plate and then still install that on the front. It's uh, is it possible? Uh, yeah. I don't think so. No, that's not gonna work. Okay, well, I'm just gonna loosen this radiator, lean it back some, and then we're just going to use the mount that came with that fan to install that unit on the front side of this radiator and that should solve the issue. Okay, so since we've decided on a pusher configuration, let's go ahead and take this radiator loose. oh, noises and another one down here. I'm not going to take those out all the way because I don't want this thing to fall down. There's a couple more on the other side, All right. So I'm not really having the easiest time here getting uh, some workable space in the front of this. and since it's almost all the way out, I'm just going to go ahead and pull this radiator out all the way and then I can fit that fan on the bench that way. I Reduce risk of damage to the unit and it'll give me more workable space to perform a cleaner installation. So I already got the upper hose off right here. The thing is draining right now. Let me go ahead and take this, uh, lower hose loose and remove that and then we'll just go. We'll put the fan on over there, uh, on the bench. Plus that'll give me more space to work on this water pump. So it's kind of a win-win I Think that's how that's gonna work. Sometimes shortcuts work and sometimes they're more trouble than they're worth. And uh, this shortcut is going to be more trouble than it's worth. so we're just going to skip that. Oh, there we go. They got me. Okay, we're over. Here 's our front side of our radiator fan unit is right here. right about the center now. I'm pointing the wires down that way If this thing ever gets wet, the water can't Wick its way into the motor. That's very important. We don't want this thing to get fouled out with water, so the install on this is very simple. Actually, we've got these four little pads right here. They're adhesive backed. Um I Don't know if they're really supposed to stick to, but they are. and uh, we've got these little pass-through zip tie looking things and these little Springs right here for shock absorption. So what we're gonna do: I Think they go this way. set up like so these are going to pass through the holes in the unit, they're going to pass through the radiator and then we will clip it on on the other side with these little Clips right here. so it's not going to go anywhere when I'm done with it. put that through right there and then we'll feed this between the fins. No, it will not damage anything. As long as you don't mess up these little cores right here and poke a hole in them. you're good to go one. Mount Push through. All right, there's the mark. You've got to have these little uh, plastic rubber insulators in there. otherwise the fan will rub through and it'll rub a hole through the cores in which case it will leak and then ruin your radiator and that would be bad. Let's rotate our trash can work bench a little bit and then the setup. Mount Number three, Peel this guy off, up and out, poke the hole and then feed it back through its little. Mark There we go Now before I I Finalize this with the the other ends of these little zip tie looking guys. I'm going to go ahead and fit this back into the Jeep and just make sure that there's clearance for everything there we go. Run these down all the way so they're not flippy flopping in our way and then that one's in. Okay, to the Jeep We go. All right. let's test fit this thing. let's see if this is gonna work. This fan is a little larger than the uh original, but it's also going on the front side here. Oh yeah, so far so good. I Think put a couple bolts in this just to make sure and I'll hold the weight. Come on you red. Oh, it's good. heavy there. Okay, there's one got one bolt in. it's at least gonna hold the weight for me. another. Okay, I think we got it. and if I push this flat like it's mounted. I.E We're looking good. Yes, it clears everything. You guys can't really see in there. it's kind of dark. but yeah, all right, that's gonna work. So I'm gonna go out, dude glab. I'm gonna grab those little clips and secure this the rest of the way. We'll pull this radiator back out and uh, I'll go ahead and attack that water pump. There they are. So all we need to do is slide these over. They click into place just like a zip tie. Give it a little tug that'll compress that spring just a wee bit and keep it from vibrating. There we go and these are now permanent I Can't relocate this fan unless I Uh plus I Cut these little guys which I don't want to do because then I have to get new ones and I don't have new ones sticks a little bit tighter. There we go. All right, fan is in. we're good. trim off this excess using flush cuts. that way there's no sharp pointy edges for people to get cut on. kind of like a zip tie. and uh, I'm gonna go ahead and pull this back out temporarily. That way we can get to that water pump, which we could probably do it right here, but it'll be easier with this radiator removed. So why not? I'm glad this thing fit it was. It's a pretty tight squeeze in there, but it fits and that's what matters. Okie dokes Next up, let's go ahead and get this power steering pump a little bit loose. that way our belt slacks off without noises it. Uh, there's no tensioner on this I think there's another one in the back? Yeah, there it is. Yeah, there's no tension around this so you just adjust the power steering pump to tension the belt if. uh. I don't like that very much at all. That's another Jeep thing. Strip bolts everywhere for everyone. Why aren't you slacking off yet? Somebody's loose. What's the deal here? Just let's tap it and see if it moves. Yeah, there we go. that's better. Get that out of here. See about uh, these pulley bolts right here. I Failed I should have done that before. I Uh. took the belt off not to worry I have some impacting kicks. Yeah, just like that. just rusted on too. No, it's not that bad. Come off pry bar I will break you if you don't come off I Feel like don't feel like fighting. It's getting late past my my fighting time. There's a bunch of rust right here on the shaft. That's what's holding me up. See you right there out. seriously. I can't stand off some of that rust right there. Lube I'm half of the hair. What is this? Pry it from two angles. man, that's on there too. Look at that ruin the pulley and that would also upset me myself. Wiggle wiggle wiggle, it's moving. it's coming off a little bit. corrosion got it? I Guess I can go ahead and pull this, uh, lower radiator hose off while I'm here. Probably gonna spill some more coolant irony this song does not. Escape Me worn out Jeep Let's go ahead and pull this idler pulley off while we're here because the bypass tube on the water pump is behind it and I need that wash your gravity I got it, It's recovered All right. Let's start losing some of these. Fasteners Here the uh, water pump is sandwiched behind the power steering pump. so I need to kind of take most of this loose and then swing it aside and I can get that water pump off. Where are we at? Right over here? take that one loose. take this one out that one out. Slide that bracket aside if I can, which I can't What else is that voltage onto? Take that out of the way and there's might be one more bolt holding this to the manifold. Where is he? Oh I found it. It's it's way back here. So I need to pull this entire pump off the bracket. It's not a factory. Bolt Home Depot Special I'm out please. It helps if you say please and if that doesn't work, threaten it. Still trying to get the uh adjuster down here. That's gotta go. That's out. This thing will be free. Please come out all right. That's what I need. It moved enough now. I Can get to that one little bolt way back there and that's holding this bracket to this intake manifold. There a little more light on the subject. We can see little guys buried back there. foreign pump, gravity incoming. Don't fall. Fetch that bolts Got it and we'll just lay this thing aside. There we go. Now we got nice clear access to our water pump. I Thought I told you to stay I Mean it. Stay there. Start pulling this pump out. Series of 13 mil bolts. Yeah, these have been in here for quite some time. There's one down here at the bottom you can't see I can't see it. but I can feel it. Get that guy out and got one more right here. Better not be stripped foreign. There she is. And our pump is free. Mostly okay welding pliers coming in. We'll unclamp this uh heater hose right here that comes out of this water pump. Bypass: Wiggle this guy off. that hose is torn right here at the tip. See it right there. All right. There's our old junkie pump. Look at that gasket. Nasty. Okay, no worries. I'm glad to see that the block surface isn't pitted or damaged or anything like that. It happens on these Jeeps dopes. The compressor is fired up. Clean out some of this and we're going to go in and polish up the surface. Get rid of the gasket material, prep for the uh, the new pump to come in foreign. I Do see a slight amount of pitting in here. It's not too terrible I Don't even know if you guys can make it out. There is a little bit of pitting in this surface, but I Don't think that's gonna pose us a problem in the future. I Think the gasket material is enough to take up for what's going on right there? Okay, let's get this thing cleaned up and oil free residue on this deal. It couldn't hurt to make it nice and shiny. You need a pressure washer okie doke. So I've got the Uh this little bypass tube for the heater core removed I Stripped off all the sealant that was on the threads and I wire brushed it. Actually a rotary wire brushed it. uh to get rid of all the rust and whatnot. I'm gonna go ahead and hit this with a coat of spray paint. Set this up for the night and I'm gonna come back at this one tomorrow morning. Alrighty, it is. A couple days later the weekend has passed. I'm trying to figure out where I left off. Oh that's right, the bypass tube on the water pump. That's where we left off. uh I painted it before I left. It was kind of rusty. ascended thing down with a little zizz wheel and my die grinder here gave it some paint so it's shiny and uh I need to go ahead and get this thing installed on. the new pump. surface is prepped so let's go ahead and get that new pump bolted back in. We're getting somewhere now. Got our pump? I've got the bypass tube set up sealed, connected, screwed in. Let's do a test fit real quick on this bad boy. Perfect Clearance is good on this side. Let's go ahead and get this thing gasketed and bolted in. So what I'm going to do here? Got the gasket in place? Just go ahead and slip two of the bolts in and hold that on. I Don't need to load this up with silicone or anything like that. We don't need to seal it because the gasket is the sealant front room and we'll go ahead and fit that thing on, get it into position and we'll start the threads and finish it off with the Uh. The other two bolts get on there all right. There's one second bolt in and pull it back some take a look, the gasket looks good. We'll get the other bolts together. there's only four, that, uh, that seal it and number four goes right now. Nice. Let's go ahead and run these bolts down. Come here, There we go. Alrighty, let's set some torque on this now. These are at a interesting torque spec because they're at the very very top of the range of my quarter inch drives and they're at the very bottom of the range at my 3 8 drives up regarding my clicky wrenches. So I'm going to pull out the digital one. We're gonna do this at the 300 inch pounds which is slightly high. It's supposed to be 270, but there was a bit of a sealant and some corrosion on these uh bolts and I don't want to uh, under torque them because of friction. Uh, where are we at? 266 and right there at 300. good to go next. radio keeps crapping out. What is this Okay, did a reset you getting torqueage now? 123, 180, 190. 200 228 Hit you guys the torque wrench. Oh 290 300. there we go. Reset again. Hello wife unit. Hey what's up babe! 300.

reset Lexai Yeah guys, what do you think? is it Lexi or Lexus IS I Like to say Lexi 307 No, that's Japanese that's Toyota she's learning we're having. We're having a learning day. Say hi, hi, you're embarrassed. All right. Anyway, that thing's torqued all four bolts. Let's go ahead and get that power steering bracket nonsense set back up and then we'll do the uh, the hoses and the pulleys and the belts and everything else. All right, let's scooch over to the other side real quick. like we're gonna go ahead and get this hose fitted. Um I think I've got enough here. where I can just cut this uh Frayed End off a little bit and get it plugged in right about there. So uh, I don't need to get a new hose just yet. Uh, like I've said before, we're kind of budget minded with this so I don't want to I don't want to rack up with extra parts if we don't have to I know I Mentioned something earlier about replacing this hose, but we're trying to keep the budget in mind here. So uh, we're gonna cut Corners where where we can get away with it? chop this guy off hose, click, slip down right there. beautiful and uh, welding pliers for the wind right about there. plenty of Slack That's good. Okay, our time is short-lived on this side of the engine. Let's go back over here and get this power steering bracket reinstalled. All right. Here's our little sneaky bolt that was in the back that I couldn't find earlier. We'll get started with that one. Maybe thread? get in there. There we go. That one's in kind of a couple more turns on it real quick there. we'll run this down so it's almost snug slippage. Yeah, it's a little too tight so it doesn't move. Now there we go. finish that off later. it goes up there. That one went there. We'll do this. one last thing. Jeep is almost done. Okay, two more 15s down here. It's funny how the water pump is also the bracket for the power steering or part of the bracket. It's a bracket for the power steering bracket. There we go. That's what it is. 13 that no that one went up here, didn't it? No. I forgot here. This one can go here. I Recall some of these bolts were not. uh, what's the word? They didn't go here and I don't think that the threads were pitched properly and I think it did strip some of the aluminum out. Yeah, look at that. There's some right there. So I'm gonna have to figure out how to remedy that situation later. All right, this is now located. Let's go ahead and snug these up squeaky clicks. There we go. All right. Bracket is now secure. Uh, too far. Okay, that was not the bolt that went there. The threads are right, but the bolt is not. I found a little shorty. Let's try that one that should be sufficient for this bracket on a bracket. Yeah, that's the one there we go. We're getting somewhere. Okay I figured out where I went wrong with this bolt. It goes in to the pump from the back side of the bracket. That's where it went. and if it didn't it's going there now. Please line up. What are we doing there it is. I'm gonna run this one down almost all the way by hand. There we go. seeing as how we found some of the aluminum threads from this bolt that came out of that bracket. That means that this is stripped. So what I'm going to do is run a longer bolt through there and uh, I will just put a nut on the other side and that will secure it properly. It works. I Mean there's still some thread in there, but it's not. It's not going to be, uh, sufficient for what we're doing. Yeah, see does not torque down and there's sparklies in there already so it's gonna work. No, it's not. Oh I need to lose this little washer thing on here. It's too big I think or grind it down. Be right back. Okay, I've got the compressor fired up so I can run the die grinder while that thing's building pressure. Let's go ahead and get the water pump pulley on. Oh look, it just goes right on. That was much easier than uh, the removal process. Four bolts, two, number three, these, uh, these all have a flat washer and a lock washer. That way they can't back off with that with a couple impacts real quick like and that will be secure. Thank you! Good to go! Okay, I've got some air pressure built so let's hit this with a die grinder and cut away this uh, this little built-in washer right here. and then we can get that bolt right there, tightened up. There we go. nice and shiny. That little washer is, uh, is gone now. So now this bolt nut should fit, should. and I'm gonna put this in backwards because if I use this face, it's not an even surface because I was just grinding on it. We'll thread that in the reverse or point it the other way. I should say words thoroughly. Coffee has not kicked in just yet. Really. try again. Welding pliers There we go. Okay, oh, that was stupid I didn't tension the belt yet I Told you guys it was early there. Let's hang the belt next. All right belt. Coming back in over under, around and through trying your shoes. I Think that's the way it wins, right? Wrong? maybe indifferent? Sure, we need more. Slack Let's push that in. How about now? Does it fit? Sure. does. Let's get our idler pulley on. As soon as this thing's clicked, we can go ahead and tension the belt. Here Comes Our next challenge of the radiator. There we go. That's toy. Let's go ahead and tighten up the belt and the pump and then lock it down. But we're good to go. Now this is not what I Remember that's fine. We'll get in there. we'll go in sideways. see it pulling the pump back out. That feels pretty good. All right. Okay, we're good and tight on our belt. Let's go ahead and snug up all the rest of these bolts that secure the pump to its bracket. Starting with this one out back kicks, look at this one up here next. it's a 14. I Can't seem to get that right? Try again. Fifth time's a charm, right? Hmm. See, they're not. that nut's spinning I mean friction? You should take care of it. Clicks. All right, that's in. And then there's I Think two more on the other side. Get on there. Oh, it's all standard size. That's my deal. Yeah, that's not a 14 either. It's not a 15, not a 14. Okay, last one is down below. it's the adjuster. There's a nut on it. Nice thing to secure that nut and we are locked down. slipped and this is beautiful. All right, this section is done. Let's see what we can do about getting. uh, getting our radiator and that new fan fitted. We've got it secured as a pusher configuration to the front of the radiator. It's bolted on. Well secured. All right. Big radiator coming in. Don't scratch it. Go. You're gonna fit I know you fit, won't you fight me? All right, let's get a couple bolts in there to secure this bad boy one right here. wrong way. Fail. there's one. Let's get the other side hung a little bit. I think they're not right there? we go. Good down below. see I won that one. Thank you Good good. All right. let's recheck clearances on this side. make sure the fan is still good because we don't want this hitting anything. Let's see it looks like that's clear. This is clear. We'll run the wire up and over and then to a new controller. Very good. Okay, we have the radiator secured I did already go ahead and put the lower hose on I've got the upper hose on those are clamped and tight with some new clamps. We've got the power steering reservoir bolted back in I Chased the threads on those little inserts right there because remember we had this uh, this like wood screw looking thing bolting this on that wasn't very secure. So I put in the proper pitch threads or proper pitched bolts and re-secure that I do need to run a new temperature relay that will actuate that fan I don't want it to run all the time? Um I Actually I May I may wire it on a switch so it can be run manually. but I've also got a thermometer or a thermostat device that throws the radiator and it's designed to kick that fan on and off as temperature increases or decreases. I'm going to install that next. Okay, first thing I want to do here is finish removing this old unit. We don't need it, it's fried, it doesn't work and uh, we have a new one. Well I mean I can use some of it. like this power wire right here. it's still a good wire. Um I don't know why this ground wire is grounded to the fuse box. I'm probably gonna move that I don't think I really care for that. We'll see. All right, let's get rid of this thing and bust out our new unit. Foreign. First one turned on and off. I mean it must have ran all the time I Don't believe it was wired properly. Anyway, we've got a uh, a new relay here. It's fused twice how we're going in and I think the other fuse is the power going to the fan. so we wire that up appropriately. Oh, it may even have a uh a wire built in for a switch. That's good. And we have a temp probe somewhere. That's this guy right here I Want to go ahead and start by getting this probe installed. We want to have it fairly fairly close to the inlet area. That way it measures actual coolant temperature as it leaves the engine. So I'm going to put that through the radiator assembly right around right here in this corner I think is going to be best and the other side has this little retainer clip. we'll just feed that over. Slide that on. please go on too handy. Get on there. All right. good to go that's on. I do have some extra rubber pads and I'm going to stick this one in on the other side over here just to just to prevent that little clip from uh scoring the fins on the radiator there. let's take a look. Got the clip? We've got the pad. we have no light. there you go, clip and pad and same thing on the other side. We've got a pad okay using the diagram and in an attempt to get this wired, we're going to start with what we know. so we've got this brown which they call this a snap switch so that's going to go and get plugged into one side of that. just gonna do these one wire at a time until I figure out how everything works. the uh, the green that goes with it or it's part of the same circuit I Believe this one runs to uh the AC AC switch. So there's no compressor here on this thing. It's not equipped with air conditioning so I don't think we have an AC switch to worry about so this might be a dead lead. I Think what I'm going to do is just, uh, temporarily wire this thing up and then I'll go ahead or just to test it to make sure it functions and then I'll go ahead and redo these connections later. So red goes to our battery power. That's power to the relay. 12 volt battery direct. Yes, that one's connected. The black wire coming out of the relay is going to go straight to ground. So let's go ahead and just ground this wire. So that gives us our relays, power supply and our relay ground. Then we just have to hook up the control circuits and again looking at the diagram. the other side of our snap switch over here goes to ignition power. So I'm going to see if I can't find a 12 volt ignition Source out here. Uh, we'll probably do that last. Okay, I've got the fan wires here. these are going straight to the fan motor. We've got a black for our ground which I'll probably ground that to the chassis somewhere and our yellow is a power supply. So temporarily just to make sure ow I poked my finger here. We'll do it like this. Yeah! One thing I I did forget to. Well, I almost forgot is I actually have to wire this backwards because we're setting this up as a pusher so the yellow is actually going to be our ground and the black wire is going to be our our hot our positive. So let's just go ahead and we'll temporarily ground that right there. or maybe right here there we go and then let's take got a jumper lead to power. see if this thing even runs. Uh, not grounded there? it doesn't. Oh, hang on there we go and we have no Okay, let's set that back down for now. it looks like this chart is able to run two fan motors, but we don't need to run two. So we're just going to use our long leaded orange wire that comes out of the relay and this one along with the blue one is labeled as uh as output. So let's just go ahead and make this connection to power right now again. I'm gonna redo these after I Test wire all this just to make sure everything works like it's supposed to and I'm not going to use these types of butt connectors either. so I'll cut these off later so that's wired that's wired good and we're still grounded with that jumper lead, we're going to substitute ignition power with another jumper straight to the battery again. Testing purposes: I've used the Uh AC switch wire I made decide to hook this one up to a fuse or I'm sorry up To a switch in the cabin. but if I were to power this wire, it should click the relay on and then actuate the fans. Let's try it out. Okay, relay hit and our fan is standing so far so good. fan towering down. Okay, let's Mount the relay and then route these wires properly and then we'll do a a good heat shrunken water type connection on all the wires and the interest of keeping this pretty. I'm gonna Mount the relay and now you can see I'm gonna Mount that right here to uh, the radiator itself. Yes, it's kind of hot. um no hotter here than it is over here on the fender. Well, so this is going to work out just fine. plus it'll make for a nice clean install. move that one more time. Relay clicks. Oh, that was a pun. Get it? I went ahead and shortened up this wire I just kind of wrapped it around itself and yeah, I could have cut it. but I don't Uh, I don't need to rewire this thing completely. So what I'm gonna do is just run this pack of wire inside of a loom. We'll zip tie it off and then plug this one in. Okay, let's trim off the excess. a couple snips just like so and then I can plug this guy back in right there that looks good. Another zip tie here that'll seal the deal I'm not going to use tape, it'll just come off and uh, one at the bottom that'll contain all that wire that's bunched up so it doesn't poke its way out through the slot in this wire. loom. There we go. I'm gonna take a zip tie or two and use it to secure these two fuses together just so they're one unit instead of two that are flopping around. I don't know if this is gonna work. it might okay. looking to the right a little bit. We do need to find a place to mount the fan motor ground. and I think I've got. yeah, that's a good ground right there so we can put an eyelet on the end of that wire and then round it right here. Pull this out, see if this eyelet fits. Yes, it does. That's good. We'll go ahead and connect this to our yellow wire here and then ground the unit. I Know it's kind of a mess right now, but it's it's going to clean up. Fear not doing this as if it were mine. and I did strip the insulation off that eyelet because I am going to install a more heat shrink. It's just a cleaner, better looking connection. Quick. Come here one more you all right? Good fire. Yeah, I could use heat gun but I choose fire. It's okay. There you go. let's run this up a little warm. Brown Click Let's uh, shorten up our power supply wire next. which is this orange one? the blue one. They're both the same circuit, but the orange one is the one I chose earlier. so I'm just going to use that one. This is probably going to end up here, so I'll make this fairly short. We'll do it like right about here. Foreign twist: I'm not going to use the uh, the solder embedded connectors I've got some of those, but I don't want to use them on this because this is a high current circuit and I fear that if it gets too hot, it could potentially remelt the solder. so I'm going to crimp them and then heat shrink them I Hope you find that sufficient. You think right about right there. Nice. Give that a squeeze connection made shrink our heat shrink. The reason I put that small piece of heat shrink on the black wire is to make the diameter a little bit thicker in case this, uh, heat shrink tube does not shrink down enough to actually make a good seal when that happens. I Just like to take it and kind of pinch it while it's hot. That'll do so. As for this dangly fuse bit I think what I'll do is just zip tie that right to the relay pack I Think that'll work Yeah, like right here. Yep, that's gonna work out just fine. Gives us good visual access to the fuses for the future in case the fan stops running. Yeah, you'd have to cut the zip tie again to change them out, but uh, it's better than just having this thing dangling around all baby puppy. I Neglected to ground the uh little black relay ground. so I'm just gonna follow fan motor ground right over and I'll ground it in the same spot. so we'll put that right here. Foreign. I'll use that same bolt to uh, sandwich it in there as well. Um, these are too small. These are super small. Here's one that's a little bigger. Fits sure does. Okay. Cut that down. need the whole piece, see how? I folded that to give it a little bit more meat. So when I clamp this it, uh, it won't be able to pull out as easily crimp complete and a little bit of heat. There we go one more time. What are you doing? Not going in straight? That's what it's doing. Foreign. Wow. All right, we're kind of nearing the home stretch here. I've got all this stuff buttoned up I Do need to find an ignition on only power supply to power the other side of this switch so it can trip the relay when the temperature reaches, uh, the appropriate level now. I Have been probing around for a while and I located. uh, not that one that's I don't even know what that one's for but I've I located this uh relay connector and it was kind of shoved back behind here and I have found that this white wire is powered with ignition on. so I'm assuming this is the designed to complete some kind of circuit when a relay is installed. I I don't know what it's for, but it's not. Um, it's not connected to anything. It could be lights. It's really tough to say but I've decided I'm going to go ahead and pull my ignition power from this. uh, this white wire right here. Now, like I said, it's not. uh, not carrying a huge load. All it has to do is supply some power to this little switch right here. and then when that switch reaches the appropriate temperature, it's going to close which is going to kick on this relay. Okay, our power supply wire is connected to that empty connector with a little Spade it runs in I've got it zip tied to the wiring harness, crosses over it, meets up with the rest of the wires that power the relay pack connected to the switch. So I think all that's left is to, uh, stop the engine and uh, see how this thing's going to perform. Oh, let's see if the fan pulls. Check this out, Watch. This fan is functioning all right. I'm gonna go ahead and start this engine. we're gonna refill the coolant. I've already got a about a gallon and a half in there, but it's going to need some more. Let's fire it up. Make sure it starts easily on its first attempt. we'll let it come up to operating. Temp And then we're going to wait for it to heat up and see if that fan comes on all on its own because that's what's really going to matter right here. So starting? Hang on. Whoa. Neutral I Doubt the neutral safety switch on this thing works okay. stocking the engine. Get a little bit of boring things action going on here. Refill this radiator. long range three. Checking it for leaks I Don't see anything dripping down there. This is good. All right. let's just stand by for a little while wait for this thing to come up to temp. at which point we, uh, we should see the fan kick on. Let's speed it up a little bit, running much better. So while this is warming up I think I'll take this opportunity to get rid of some of this power steering fluid that's uh, it kind of leaked out on the reservoir. Oh yeah, yeah. I bet you didn't think that was gonna happen. did you? just a little bit of nice and shiny? Details Matter Okay, let's check our temp. Uh, the gauge says we're right at 210 where we're supposed to be. We should start to see the span. Come on any second. Now here's what we're gonna do. Go ahead and get this out of the way and we'll let it suck up the piece of paper. you know it's on. Okay, we're seeing 190 at the coolant temp sensor. You got here. All right. We're right here. at the coolant temp sensor. We're 188 190. You guys see that 207 upper hose is 194. Fans, run. Let's go check our gauge. where'd we land? at? What that says, it's like 225.

oh what about all that? It's actually measuring 195. And the 10th sensor? What do we got? 179? That's a little though. 204. All right, so that gauge is a little off. Probably resistance or something in the wire. Let's check the lower hose 148 150. 50 down, a little closer just to make sure. And yeah, it's saying 145.

okay we are fully cooling. Supposed to be Atty at the radiator 182. All right, it's doing its job all right now. Let's let it hang out and make sure it stays cool. and then we'll go out for a test drive and make sure that the uh, it's actually going to run under load because I have not been out on a test drive. Oh that's pretty cool. So uh so the wife unit. She was in the office and she made some, uh, some new merchandise. a couple stickers and some T-shirts There's a nice and shiny sticker and a wife unit shirt. Those are what else did you make wifey in it. Nice and shiny. Where's the light theater? All the wives are white people. So anyway, it has not even been posted onto the YouTube Banner yet. You know the woman shows up below the video and she said some folks already went and bought some nice and shiny stickers which that is awesome. Good job babe! Good job. Tell you what. I'm going to retire off the wife unit. She's going to sell like t-shirts for days. Especially okay. What other one did you do? Let's go see. Seriously, here's the deal. if everybody here just goes and buys a sticker. I Can retire tomorrow. Nice and shiny? Yeah. nice. I Like them? What do you guys think? I I Like watching it the best. I Love it. All right? I Got a jeep that might overheat I'm gonna go check on that bye oh look and the fan shut down on its own. Oh it's great that we caught that. Do we? It's doing what it's supposed to be doing. Let's check the temp again. Okay, it came down to 210 so that's about right. Okay, well I like it. Very pleased with this one. All right. let me pack out my goodies and uh, get the truck out of the way and we're gonna go out for a test drive real quick. like backing out. it's a Jeep I'm still not done yet though. we do need to get this up in the air Am I in gear. Nope, we do need to get this up in the air there that's reverse and uh, look for that clinky, rattly noise down below. Um, we are gonna do an oil change on this later and I do need to do just a general undercarriage inspection. Well, we held off on all that work until we could actually get some traction on this thing's running condition and overheating issues. And now that that stuff is solid, we're free to proceed with, uh, additional repairs. But I'm glad this thing is going to live on. There's not many of these old. Jeeps left ring ring here we go. Light throttle Full Throttle right here. Nice foreign guys I'm gonna run for about a mile or so down the road. just make sure this thing stays cool and uh, that's gonna about uh finish this one up. As always like thank you for watching this video. Hope you enjoyed this video. If you did enjoy this video, just let me know about that by tapping that like button down below. So again, and as always, thank you for watching. And most importantly, don't forget to have yourselves a great day! See you guys later! end of transmission That's all.

98 thoughts on “Old jeeps die hard! thermostatic switch and water pump! 95 wrangler 4.0 new shirts for black friday!”
  1. Avataaar/Circle Created with python_avatars Steven Baker says:

    There are NO metric fasteners on my Jeep!…. an '85 Grand Wagoneer. Still going strong at 188,000 mi.

  2. Avataaar/Circle Created with python_avatars Jonas Kadah says:

    Happy doodeeleeedoo-giving! hint hint

  3. Avataaar/Circle Created with python_avatars Craig InBoro says:

    Are you sure you put the belt back on right?

  4. Avataaar/Circle Created with python_avatars scrapinby77 says:

    Is the "Bog Deep" stamp on your hand from Cleetus and Cars?

  5. Avataaar/Circle Created with python_avatars Alan Cutler says:

    Hi Ray, great to see you up and running again and running your own business with some family support. Great video re the Jeep, but not convinced that attaching the fan through the ultra delicate radiator fins is a good idea and will result in a leaky rad before too long. Appreciate that is the suppliers recommended way to fit them, but not convinced.

  6. Avataaar/Circle Created with python_avatars blackwolf8281 says:

    Great to see you hit the ground running Brother Ray.. You went from workin for the man .. to being the man..LOL😎.. Now you have the freedom to spend more time with the family and do things your way without the corperate B.S… Wishing you and the family all the best and Happy Thanksgiving!!

  7. Avataaar/Circle Created with python_avatars Michael kunzler says:

    Ray nice job.

  8. Avataaar/Circle Created with python_avatars Steven Baker says:

    She rips now Ray! Excellant!…good job.

  9. Avataaar/Circle Created with python_avatars John Thorpe says:

    I got a jeep that might overheat and I'm a poet and don't know it… the rhymes without intention.

  10. Avataaar/Circle Created with python_avatars ramon gabatel says:

    hi Ray, please don't offend it ..For your health please never work with rings in the fingers, I'm a machinist and is asking for injuries….. like very much your program

  11. Avataaar/Circle Created with python_avatars Dave Faulkner says:

    Loving all the new content,
    Going out on your own best thing you ever did.👍
    Keep up the great work
    Cheers from down under👊👊😃

  12. Avataaar/Circle Created with python_avatars tony ly says:

    Happy Thanksgiving. Love all your videos.

  13. Avataaar/Circle Created with python_avatars James Fry says:

    Love your Vids Ray and your getting wrong sockets makes me feel good as I do it to keep up the vids your doing great and good to see your family involved so thank you from Australia 🇦🇺

  14. Avataaar/Circle Created with python_avatars Rennia Trayvold says:

    Loving this Jeep series so far! Great job on fixing the power issue and the overheating! Can't wait to see your work underneath, that short clip you showed made me nervous for sure 😅

  15. Avataaar/Circle Created with python_avatars Fubarnow says:

    Clothing is Nice

  16. Avataaar/Circle Created with python_avatars Björn Sparf says:

    Are the fan blades shaped in a way that you can choose any direction? Nice job! Who’s working in the background?

  17. Avataaar/Circle Created with python_avatars Tibor Velcek says:

    Hay Ray you all so need actually clicks and gravity Tee shirt 👕 😁😁

  18. Avataaar/Circle Created with python_avatars William Duhamel says:

    Metal on metal without bushings? Yea, that would be noisy

  19. Avataaar/Circle Created with python_avatars wolvenar says:

    It would seem like those foam pads would disintegrate within 5 to 10 years leaving the radiator open to damage

  20. Avataaar/Circle Created with python_avatars Gert Coetzer says:

    I would have run ignition strata to the battery for cool off time after the ignition has been switched off.
    You forgetting: Gravity and clicks

  21. Avataaar/Circle Created with python_avatars Frank Baber says:

    Glad you added hole family unit,did think radio was broken when Rapp came on, but you fixed it.

  22. Avataaar/Circle Created with python_avatars DOUGLAS BURFORD says:

    Real Jeeps have round headlights.

  23. Avataaar/Circle Created with python_avatars Steven Baker says:

    Don't be shy with the PB blaster Ray. Crusty Jeeps like it! Especially up north here…mines devoured a lot of it!

  24. Avataaar/Circle Created with python_avatars Tim Davis says:

    Why does it feel like Ray is making this for himself and his "wife unit"?
    Oh, and that belt went under the pully before and now it's over the pully on the water pump. Still turns right so probably better that way anyway.
    Hope you guys had a great Thanksgiving. Hug the wife for designing the shirts. Might have to get mine one. Take care.

  25. Avataaar/Circle Created with python_avatars Wade T says:

    Happy Thanksgiving Ray. Hello to the family!

  26. Avataaar/Circle Created with python_avatars Gary says:

    Ray I have been watching your videos from the UK for a while now . This Jeep fix was so Impressive how you tracked it down and sorted it out then redesigned the cooling system , Awesome job .

  27. Avataaar/Circle Created with python_avatars Sandmansa says:

    I'm glad to see that you got the go-ahead to fix the cooling system problems. But I have one question Ray. What stopped you from using the coolant sensor that was pre-installed on the upper radiator hose? My past experience with Hayden fan systems with temp sensors that are installed between the cooling fins of the radiator, are nowhere near as accurate as sensors that are actually in the coolant flow. Yeah, they work in a pinch. But the accuracy is drastically affected by rain, snow and high winds.

  28. Avataaar/Circle Created with python_avatars Casual Carver says:

    you need to make a "WRENCH UNIT" Shirt and sticker!

  29. Avataaar/Circle Created with python_avatars ben says:

    any more news on that mustang near miss?

  30. Avataaar/Circle Created with python_avatars WACKO1123 says:

    I do love watching your videos. But this one you disappointed me. First you really should have removed the rust from the pulleys it will abrade the belt until it smooths out.
    More importantly you put the belt on in a different configuration than it was when you removed it, in doing so you have reversed the direction the water pump spins. Originally the belt was under the water pump pulley and you installed it on top of the pully, thereby reversing the pully spin direction.
    Lastly, you cannot just reverse the spin direction on a fan to change from a pusher to a puller. That can only be done with flat blades. The fan blades you have are radiused and contoured to maximize the CFM and you are losing a huge amount of that potential.

  31. Avataaar/Circle Created with python_avatars Ken Eagle says:

    Had a good chuckle when you showed that rear suspension.

  32. Avataaar/Circle Created with python_avatars Jean Meslier says:

    I had a 1968 Dodge B200 van. Chrysler had just introduced their first high tension ignition system.
    The distributor cap and the rotor especially couldn't handle the voltage. The wiring and spark plugs along with the other stuff failed almost exactly at 25,000 miles. In the distributor cap you could see the trails of soot where the mis-fires were occuring. I learned to replace everything at every 25,000 miles. Now at the Chrysler dealership, the cost was horrendous to buy the parts. The system was made by United Technologies. I discovered my local Kmart had all the components,, plugs, wiring rotor and cap for less than $20. The same United Technologies and part numbers.
    Since repairing cars was my side hustle, I repaired several. The dealers would diagnose everything from engine overhaul, valve job, replace air intake system, but as far as I know never the electrical system. Which was a mystery to me as that was something we checked first on older vehicles.
    The high tension system enhanced the performance of the ignition system comparable to the transition from 6 volt to 12 volt.

  33. Avataaar/Circle Created with python_avatars Joe Pollock says:

    The more we all watch these videos, the more we realize you’ve massively outkicked your coverage with that wife-unit. Congrats man!

  34. Avataaar/Circle Created with python_avatars Johnny Lee says:


  35. Avataaar/Circle Created with python_avatars Roger D says:

    Wife Unit? you make her sound like just another tool. Cant believe she doesnt take offense to that

  36. Avataaar/Circle Created with python_avatars Mark Caldwell says:

    Helicoil!!!! MECHANIC UNITS….I SWEAR! 🤣🤣🤣

  37. Avataaar/Circle Created with python_avatars Mick Ralph says:

    Well done. I thought that was a basket case.

  38. Avataaar/Circle Created with python_avatars Cherokee2005 says:

    Awesome video!!!! Great work bro!!!

  39. Avataaar/Circle Created with python_avatars Daddyoh says:

    Seat Belt Ray….

  40. Avataaar/Circle Created with python_avatars David Jones says:

    One of my favorite videos! I'm kinda partial to the straight 6. I have 2 xj,'s; a 94' and a 95'. They run like clocks!

  41. Avataaar/Circle Created with python_avatars Cheezunrice Ramen says:

    Does it matter that the belt isn't running in the same path?

  42. Avataaar/Circle Created with python_avatars Brian Webb says:

    Now you are working for yourself you can finish jobs to your standard and not a standard that you are told to do.Good to see you so happy now and having your family around.

  43. Avataaar/Circle Created with python_avatars Steve Smith says:

    "I'm doing this as if it were mine" is the best way to do any customer job. Happy Thanksgiving, and so happy to see you taking the effort in all that you do!

  44. Avataaar/Circle Created with python_avatars Michael Denney says:

    I've really enjoyed seeing you revive this old jeep. 😉

  45. Avataaar/Circle Created with python_avatars patrick cowan says:

    With the cleaner. South Main Auto Repair.

  46. Avataaar/Circle Created with python_avatars MikeHillman says:

    Great work on the Jeep. Was looking at your placement of the relay for the fan and have a question. Will there be any negative effects of mounting the relay that close to a heat source? Not so much about risk of fire, but more so the risk of malfunction and/or burning up faster because of it being so close to heat source as well generating a lot of heat while 20-30amps of fan running?