Just a few updates. I believe I have most all the wiring figured out and mostly completed at this point! There is only the contour fans and a few other things to finish hooking up and the engine side of the harness should be completed. While I had all the wiring apart, one of the many wiring mods I did was I went ahead with the headlight wiring upgrade using two of the relays and fuses in the XJ PDC. I ran 12 gauge wiring for the headlight power feed and grounds. The high and low beams are isolated in separate fuses and relays so no matter what could potentially happen, I will always have some form of headlights that will work! For the headlight connectors I used a pair that is made of ceramic and has a sealed back so dirt and junk can't get into the connection. I got the terminals from Innova Design & Distributing, Inc. the have several different wire gauge sizes, wire lengths, and the option to crimp, solder, or do both where the wire is connected to the terminals. Here is the website:
http://www.itroll.us/H4.ht.html or headlightplugs.com
The terminals are crimped and soldered.
I also was able to clean up, inspect, re-seal, and repaint the transfer case.
Transfer case re sealed and reprinted:
I pulled the yoke and front driveshaft from the 93 XJ I am parting out and put it out the rear output shaft of the dana 300 so I can run a CV style rear driveshaft. I plan to have a local shop modify the driveshaft to work.
Being that I'm running the AW4 I needed to run a clocking ring/spacer so the input shaft on the dana 300 would seat correctly. This also meant I needed to run a double sided seal on the input shaft on the dana 300. I messed up the edge on the first seal installing it and didn't want to take a chance of it leaking so I went ahead and put another new seal in to be safe:
Here is a part number for the double sided seal I am using: Moog 710928
Once I get the wiring for the ford contour fans completed and the transfer case installed I will get back into the body work. With work (insanely busy) and a family my jeep time is limited to 9-midnight a few nights a week but I am managing to make some progress! I am able to take some time that was dedicated towards my new home and get it back to my Jeeps since the house is done ; minus the yard and landscaping. My daughter also has another major announcement to make for her birthday:
Yep, my wife and I are expecting our second! Her tentative due date is October 28th so the completion date goal for this postal is set for mid October!
And because I don't have any specific GW pics, this is the best I can come up with!
Here is the parts truck '93 XJ, I have what's left of it listed in the classifieds:
Sent via signal flare