A YJ for my Dad

[eric m]

I thought I’d put up a build thread on the 1990 YJ Sahara I’m building for my Dad. He bought the Jeep in 2015 or so, he drove it in the summer of ‘15 and ‘16 then had issues with it and parked it. Fall of ‘19 he decided he wanted it fixed up and turned into a driver.

What I started with:
-1990 YJ Sahara
-carbed 4.2
-Ax-15 with internal throwout bearing (that leaks)
-3” body lift (&#129326
-damages front fender

The plan:
-Holley efi
-Advance adapters external slave cylinder upgrade (new bell housing etc..)
-Flat fenders
-Rocker protection
-New exhaust
-Change 3” body lift for 2” suspension and 1” body
-Fix rust on tub
-Spray line inside and out.





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[eric m]

The Jeep came with a hardtop and 3 different sets of doors, my Dad settled on the half doors and I found the slider uppers on Craigslist.


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[eric m]

Started by replacing the factory gas tank skid with a Warn hd skid. Also replaced the rotting exhaust with a Banks Monster exhaust (91-95 yj, fits the 90 just fine.









This was the front flat fender adventure, a lot of by guess and by golly with a grinder and I got them fitted up nicely.


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[eric m]

We started with dumbo style Xenon fender flares someone thought looked good and the factory body mounted side steps...






...and went with these metal narrow rear fenders.




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[eric m]

Then it got fun, what should have been a simple 1 hour job turned into 3 days of fun and adventure when it came time to ditch the 3” body lift. The frame on this Jeep is immaculate no rust looks showroom new so I figured the tub would be very clean...


This is metal rusted to plastic...which isn’t possible but yea. 3 of the 9 mounts unbolted the others fought me tooth and nail but in the end I won.



I went with Daystar’s 1” body lift/polyurethane body mount kit.






I went with a BDS suspension 2” spring lift front and rear. I did add Rough Country front sway bar disconnects as the factory ones are shorter than I liked. I will also be adding Crown extended brake hoses as I’m not a fan of the relocation brackets.


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[eric m]

My dad didn’t want the hardtop as he’s not driving this in the winter when it’s done. So I got creative, I decided to add a bowless TJ soft top...







I found a TJ in my local wrecking yard (much to my surprise) I cut the top retaining bits off the tub and drilled out the spot welds before welding them to the YJ tub.



Scored the doors surrounds from same TJ for $10, here they are located on the YJ where I drilled out holes to accept them.





I used a Rampage header and top, this is where I had a moment of not thinking and ordered a tan top. I will be dying the uppers to match and making some top supports the clamp to the cage to lift the back of the top over the rear seat. Right now it looks like a CJ rally top that won’t last.



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[eric m]

This about where I ran out of warm weather and I wanted my garage space back...
I have the advance adapter kit and a new clutch to swap in, however I will drop the the exhaust from down pipe and cat which is so rusty it needs replaced. I will probably replace the manifold due to rust as well at the same time. Also when I lowered the body it took out the seal in the steering box which needs replaced, I have a Fabtech steering box skid plate to install when I do that in the spring. I will be installing an efi kit and spray lining it as well at that time so stay tuned.


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