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theksmith

TheKSmith's 2003 Jeep Grand Cherokee WJ Limited 4.7 H.O. - The Do-It-All Rig

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Cool. Sounds good! Thanks.

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I like it!! Looks like a good base to add to and customize. That's one of my big concerns with taking my son out. With the WJ being so top heavy and tippy already it is a great upgrade. It's also an easy one to convince the wife. Safety first.

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while messing around with the t-case i found a couple other issues...

 

 

shift linkage grommet

 

the grommet that helps hold the shifter cable on was missing. this is common problem in some JK's too. fortunately the way my cable is routed, the end will stay on and still work - but now i know why i had a sloppy feeling shifter.

 

i found several people online talking about a better fix than just replacing with a factory grommet. everything you need is in the "help!" section at most any auto parts store:

 

IMG_5821.JPG

 

IMG_5820.JPG

 

supposedly you use the smallest grommet from that pack and then the e-clip that measures 3/8" O.D. to clip on outside the grommet and help hold it on. i'm not sure if the material of these grommets is better than the factory or what, but several people reported their fix has lasted years. i grabbed the parts but haven't been back under the jeep to do the fix yet myself.

 

 

there's the leak!!

 

i've had a nasty t-case leak for a while now and i thought it was coming from around the shaft of the shift arm. it turns out i am just missing a rubber plug, Mopar part #15105. see the shiny clean hole right in the edge of the light?

 

IMG_5780.JPG

 

i tried to find a replacement from Ace that would fit, but none of these worked:

 

IMG_5781.JPG

 

i can't think how this would have come out unless maybe my breather line is kinked and it got pushed out from pressure... anyway i ordered 2 replacements and we'll see what happens once i get one put back in (no shipping info still after a week now, so who knows when i'll get them)!

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while messing around with the t-case i found a couple other issues...

 

 

shift linkage grommet

 

the grommet that helps hold the shifter cable on was missing. this is common problem in some JK's too. fortunately the way my cable is routed, the end will stay on and still work - but now i know why i had a sloppy feeling shifter.

 

i found several people online talking about a better fix than just replacing with a factory grommet. everything you need is in the "help!" section at most any auto parts store:

 

IMG_5821.JPG

 

IMG_5820.JPG

 

supposedly you use the smallest grommet from that pack and then the e-clip that measures 3/8" O.D. to clip on outside the grommet and help hold it on. i'm not sure if the material of these grommets is better than the factory or what, but several people reported their fix has lasted years. i grabbed the parts but haven't been back under the jeep to do the fix yet myself.

 

 

there's the leak!!

 

i've had a nasty t-case leak for a while now and i thought it was coming from around the shaft of the shift arm. it turns out i am just missing a rubber plug, Mopar part #15105. see the shiny clean hole right in the edge of the light?

 

IMG_5780.JPG

 

i tried to find a replacement from Ace that would fit, but none of these worked:

 

IMG_5781.JPG

 

i can't think how this would have come out unless maybe my breather line is kinked and it got pushed out from pressure... anyway i ordered 2 replacements and we'll see what happens once i get one put back in (no shipping info still after a week now, so who knows when i'll get them)!

 

If the tapered plug on the right will start in, try drilling a hole in the center, then use either a machine or sheet metal screw to make the rubber plug expand in the hole. Might work as a temporary fix until you get the correct part.

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Good news on the Rockhard cage! I'd seen these pictured in an add at some point but couldn't find them on their website. Maybe they were still in development. Glad they've finally got to production!

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i finally got around to working on those issues with the t-case...

 

the shifter arm bushing

 

i was able to use the smallest one of the bushings i bought, but i had to drill out the plastic loop on the end of the shift cable one drill size larger.

 

IMG_5821.JPG

 

IMG_6144.JPG

 

after sliding that all the way back on the stud, there was room for a thin washer plus a retaining clip. i used this style clip instead of the e-clips i bought as it felt more secure (not sure what these are called):

 

IMG_6146.JPG

 

IMG_6148.JPG

 

hopefully that keeps this minor issue from happening again.

 

 

the missing plug

 

since the factory rubber t-case plug was backordered, i went to Ace hardware again to find one that would fit better than the first few i had tried. i planned to give mbuckner's idea about the screw a try, but found just what i needed there instead (along the same lines)...

 

again, i don't know what this is called - it's a rubber plug with a center hole. the far end has a threaded piece of metal bonded inside it. you put a screw and washer on and when you tighten it down it bulges out creating a secure plug.

 

IMG_6134.JPG

 

IMG_6135.JPG

 

IMG_6136.JPG

 

this should stay put, or else i must have another problem that is causing the plugs to pop out in the first place.

 

IMG_6154.JPG

 

tomorrow i still need to top off the t-case again.

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Kris,

The metal "washer/clip" you used on the linkage is called a bolt retainer, and come in a variety of sizes. They are typically used in production situations, to hold a bolt in a blind hole during assembly. They are most often used with a carriage bolt, which then does not require the bolt head to be held with a wrench.

 

The expanding rubber nut you used is called a "well nut". They are typically used for blind mounting things like roof racks, and in the marine world for mounting of fish finders, trolling motors, etc., as well as in the electronic industry for isolation mounting of circuit boards, etc.

 

You may find that in order to completely seal it, you will need to clean the threads and add a drop of RTV or similar sealant to keep the fluid from migrating thru the threads.

 

;)

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Kris,

The metal "washer/clip" you used on the linkage is called a bolt retainer, and come in a variety of sizes. They are typically used in production situations, to hold a bolt in a blind hole during assembly. They are most often used with a carriage bolt, which then does not require the bolt head to be held with a wrench.

 

The expanding rubber nut you used is called a "well nut". They are typically used for blind mounting things like roof racks, and in the marine world for mounting of fish finders, trolling motors, etc., as well as in the electronic industry for isolation mounting of circuit boards, etc.

 

You may find that in order to completely seal it, you will need to clean the threads and add a drop of RTV or similar sealant to keep the fluid from migrating thru the threads.

 

;)

 

thanks for the clarification on the names OB.

 

and yeah, the RTV thing occurred to me as well - AFTER i put it all back together! i filled up the tcase and have a small leak (instead of a massive gush at least), so it looks like do need to RTV those threads.

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about ready to Do Work...

 

IMG_6195.JPG

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