Trying to keep the wiring rat’s nest to a minimum, I created a Fuse and Relay box.
Parts list:
1 Project box a la Radioshack
1 Power distribution block
1 Fuse holder
4 Appropriately sized relays
4 Appropriately sized fuses
Various wires and connectors
I started by bridging the power distribution block followed by mounting it to the side of the box. The 4 fuse block was mounted to the lid.

I then drilled two holes in the lid for power access to the relays the box will contain.

I busted my turn signal stem today and, apparently, you can't get just the stem from dealerships anymore. They sell the stem and switch as a single unit for $144.
I ordered just the stem from JeepsAreUs. I have never used them before so we'll see how it goes. Roughly $36 including shipping.
JeepsAreUs
I'll comment on the post when I billing hits the card, I get notification of shipment and receive the part.
My armor setup on the YJ is finally complete.
All that needs to be done is sealing and paint touch up.
Thumbnails are of the front armor, more pics of the rear armor as well, after the jump.


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Installed a 2" budget boost... coil spacers with new slightly longer shocks.
While in the process of removing the springs, one of the swaybar links failed.... or i should say came apart:
sooo... got a new one installed and all back together... YAY!
Now, just need to get that door fixed.
Recently I had a slight battery drain issue which I narrowed down to the stereo install. Apparently there was power applied all the time, regardless of ignition switch position. Even with the unit off, there was a significant draw.
I did some digging and found a wiring diagram for the unit.
Brown, phone mute. (unused)
Yellow, 15A fused, memory backup lead. (needs power all the time)
Yellow, 3A fused, bus power. (needs power all the time)
Red, power. (needs power when ignition is on position)
Blue/White, amp turn on. (not used at this time, but will in future)
Black, ground.
Orange/White, illumination. (connect to light switch?)
Blue, auto antenna. (LOL, on a YJ? unused)
So now I have to figure out where all this is SUPPOSED to go in the wiring harness.
A laundry list of items to be installed.
XRC8 Winch
~400W Inverter (40A)
2x 100W SRS Lights (20A)
12V Air Compressor, OBA (30A)
12V Power Port (20A)
In theory, I’d like to have a power distribution point under the hood and in the cabin area provided the items connected don’t draw too much amperage. Clean wiring is the name of the game.
Everything that can will have a relay connected to an illuminated switch to indicate power is applied and system is active. All items will be fused as well.
The winch remote plug-in will be mounted in the switch panel.
The first order of business is to estimate what the max draw of each of these items.
Since it's too cold out to actually do any work, it's time to make plans for the future.
I need to work on multiple systems on my YJ. Recovery, electrical, suspension and a seeping leak etc.
Recovery:
Luke over at Frontier 4x4, is currently designing a front bumper to house the Smittybilt XRC8 I will be buying soon.
Move hi-lift to rollbars or hood.
Electrical:
I will be putting LED replacement dash lights in. Half the bulbs I have are burnt out.
Get gauges working or replaced.
Alternator upgrade for winch use.
Install dash speakers.
Install 12Vdc air compressor.
Wire in XRC8 winch.
Leak:
I have a small leak at the transmission cooler that needs corrected.
Suspension:
Finally trim u-bolts.
Install bump stops.
Brakes:
Adjust E-brake
I'll add more as I think of it.
Update on the Trailcutter MTs.
I just drove about 25 miles on their first snowy roads. I must say they behaving admirably for a mud terrain tire. I can only assume that it is because of the factory siping. We had about 3 inches of snow and my commute is about the same time the plows get started so most of the roads were still covered.
Anyone who wheels Jeeps has mostly likely done it. It was done to my YJ just before I bought it.
What I'm talking about is chopping the exhaust. Whether it be a rock or your own axle, your exhaust system will get crushed at some point.
The trail fix for this is usually cutting the exhaust pipe off just behind the muffler.
Well, I ignored that mine was cut off too long. Coming home from a wheeling trip (I race on Sunday what I hope to drive on Monday) my ignition coil failed. During the failure, it loaded the exhaust with fuel and expunged everything out the muffler. This is when I suspect my problem really began. It began with a fireball exiting the muffler which was pointed directly at the fuel tank skid plate with the fuel tank inside.
Nothing went wrong immediately. I borrowed an ignition coil off a club mate's jeep and drove home.
Subsequently, a couple months later, I'm filling up at the station when I notice gas running everywhere. After scrambling for some oil-dry, I was able to see that the fuel was exiting near the tank straps, but that's all I could diagnose sitting at the pump. The one and only time my Jeep has left me dead on the road, and this was it. I had to call a flatbed truck to take it from Newton (Iowa Speedway) to home.
After ordering a new tank and getting everything torn apart, I noticed the passenger's side of the tank was severely deformed. It had melted to the skid plate, thinned out, and finally cracked under the pressure of the strap.
This could have been ugly, real ugly. I got lucky.
Moral of the story is, carry a turn-down. You won't regret it should you have to cut your exhaust.
Best case, a 20 US gallon, fuel tank for a 1994 YJ will run you about $400 delivered.
Worst case, your tank ignites costing whatever your junk is worth, if not your life.
A turn-down will cost about
6 bucks.
The axle swap was completed at the beginning of June, but it wasn't until now that I had a chance to to get it out wheeling.
Along with the axles, I installed a new set of shoes. Trailcutter MT's. Everything perform as was expected. Nothing broke on the trail, though I did burn up the ignition coil on the way home. I was able to scavenge one off a trailered rig to get home (Thanks Jim!).
Since then, I installed a new coil, cap and rotor. Everything seems to be running fine.