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Super Moderator
2004 AiRubicon
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Discussion Starter · #1 · (Edited)
OK folks, time for me to start a build thread for my New to Me 2004 Jeep Wrangler TJ Rubicon.
My wife has named it Boo Boo for some silly reason because of the Geico commercial with the bears and some of the trail pin striping.

Here are some pics @Elwarpo sent me, so we have a base to start with.
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As you all can see, it's a properly used vehicle, in it's natural element and a fantastic base that is very solid mechanically. It has a couple of key items which made it a perfect ElffMobile.

Key things
AiROCK with OnBoard Air
Cross Over Steering
Out Boarded Shocks
Stock Moab Rims
MAC's CAI
Cool Locker relocation to get them out of harms way
Hard Top
A bunch of spare parts.
 

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2004 AiRubicon
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Discussion Starter · #2 · (Edited)
While working out the sale, it was made known to me about the crack in the windshield. I fortunately have a great glass company 1 town over from where I work, so I let Mike know I would take care of that and actually scheduled that work for Wednesday this week and it's already replaced. Funny thing is, they transferred over the Inspection sticker, so as long as no PA Police notice the Sticker does not match the Plate state, I could go months without it being inspected.
LOL
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Blue tape is to let the seal settle and I left it like that until Saturday morning.
 

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2004 AiRubicon
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Discussion Starter · #3 · (Edited)
Initial items that required immediate attention that are all squared away
Ran a new Airline to the Passenger rear Airbag and zip tie it above the heat shield.
Replaced the Circuit breaker in between the battery and painless wiring harness
Replaced the on Board Air 1 gallon tank
Replaced some push fittings for the AiRock.

Items that need to be looked into
Adjust the parking brake
Install the 2 new Spare Front shocks.
[I can then rebuild a full backup set and be able to do this for the life of the vehicle]
Investigate the Rear Locker. It was working on delivery but for some reason would not engage yesterday. As such, this is probably something really simple. Pump is working, so I will check for air leaks first, then move on to other troubleshooting
Clean up some surface rust.
Clean and vacuum the interior.

Yup, that is literally the list of issues. For a vehicle made in 2004, that's amazing. Kudos to Mike for keeping Blue, now Boo Boo, in great mechanical shape.
His dusting, cleaning and vacuuming skills, however, need some work
:ROFLMAO:
 

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2004 AiRubicon
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Discussion Starter · #4 ·
My wife has CDO. She is so OCD that she alphabetizes it.
She is also a professional detailer on the side and was having agita over the state of the interior.
As such, We ripped out the original floor mats and have a full new set waiting to be installed.
I also ripped out the roll bar padding and covers. [I am not tall enough to hit my head]
The wife then went to town on the interior and I simply got out of the way. Multiple dining out dinners will be the payback for this. LOL My wife wants to touch it up one more time, but to me, it looks like it just came out of the showroom

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2004 AiRubicon
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Discussion Starter · #5 ·
So that's about all I was able to get done because PA decided to feel like TX this week. Instead of working on the jeep this weekend, I already took it 4wheeling at Rausch Creek in PA. It performed great shy of the rear locked being finicky. I will address this when I change all of the fluids.

Boo Boo was all ready to go and was looking good Saturday Morning. My wife even refreshed the flares.
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Boo Boo in his natural environment
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And set to Offroad Height.
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After a full day of wheeling in some soupy humid and hot mild wheeling I have to say it was an absolute pleasure to drive home 1.5hrs.
I rolled up all of the windows, cranked the AC which felt SOOOOOOO good, and set the cruise control to 70mph.
I can drive with only a single hand on the steering wheel it is so stable. Once I replace the front shocks it will be even better.

Any way.
It's not even 1 week since I got the jeep and things are looking great.
More updates on the way.
 

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Looks really good!
 

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What is this dusting, cleaning... thing you speak of?:oops:
Notice how he busts me but then has someone else do it... slacker
🤣
 

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2004 AiRubicon
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Discussion Starter · #11 ·
Today I installed new Yokohama Geolander M/T G003 315/75r16 tires and put in the rebuilt front shocks. It really tightened up the street handling and going down 1 tire size will significantly preserve my drivetrain. Got a buyer lined up for the 37s already to offset the cost
Also removed the soft top and re-cleaned the interior in preparation for all new floor carpets, mats and a cool soft top/tonneu combination that I will run until November in which I will put the hard top back on.
OO I also rust corrected the Jeeperman skids and put a fresh coat of paint on them. Same for the rear cross member while I wait for the rear bumper to get here. Gonna hit the stock Rubicon Diamond plate this weekend after we give the outside a super deep cleaning, touch up the paint and polish it.
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Very nice rig.. little clean up and some rust preventative and good to go. I love the tire selection and list of parts it has already. Best part is it’s ready to go!
 

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You do know I had nice 35s on Moabs that I could have given you instead of the 37s you wanted...
 

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2004 AiRubicon
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Discussion Starter · #14 · (Edited)
O man, I thought you said the 35s were on steelies with Staun internal beadlocks and the Moabs had the 37s. I figured the tires did not matter. I was more interested in stock Moabs. They are truly one of the best rims ever made. No worries.
FYI these new tires balanced with practically no weights. I am very happy with them so far and am looking forward to see how they do on rocks

Almost done with the new carpet install. Just need to do the wheel wells and then I will take more pics to share. i am very impressed with the Quadratec kit. The pieces fit great and its made in America
 

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2004 AiRubicon
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Discussion Starter · #15 ·
Finished up the New Carpet install and front floor mats. I am going to get ones that go behind the seats as I put my tool bags there, and get a large one for the back area, to protect the carpet.
The front Mats and the ones behind the seats were bought for with beer. :ROFLMAO: A coworker of my wife gave them to us, so we thanked him with some craft beer.
Anywho, MOAR PICS!!!!

Front Driver foot area
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Pic of the carpet tucking under the center console
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Passenger foot area
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Close up of the carpet tucking under the center console on this side
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Behind the rear seats
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The rear cargo area
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The notches on the side pieces are for the seat hinges, which I don't have. So they were by design.
I did pull out the center console to install this and now that locks down the front and rear sections nice and tight.
The longer the carpet sits, the more it conforms to the surface. Only thing left for me to do is cut out some slots for the remaining tie down locations and I am going to put some velcro in some corners.

If anyone is looking to do this, Here is a link to the kit I got. I highly recommend it.
 

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I no longer recognize her lol.
Looking good.
 

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What is this dusting, cleaning... thing you speak of?:oops:
Notice how he busts me but then has someone else do it... slacker
🤣
ahhhhh the good O daze ....😂😂🤣🤣
 

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Super Moderator
2004 AiRubicon
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Discussion Starter · #18 ·
Did a couple of things today.

Elff Mod. [I'll let people search that to see if they remember this]

Painted the stock diamond plate to freshen it up
Painted the top, bottom and outside of the frame rails with some rust specific paint.
I will go back and do the insides on another day.

I troubleshot the rear locker as the dash light just blinks. I went through the following procedure
UNLOCKED Checked out
(1) Block tires opposite the axle to be tested to pre- vent the vehicle from rolling.
(2) Place transfer case in 4WD Low and automan- tic transmission in Park (1st gear if manual trans- mission).
(3) Raise both wheels of the axle to be tested off the ground.
(4) Turn ignition to the ON position and dash switch to the OFF position.
(5) Rotate one tire by hand. The other tire should spin in the opposite direction.
LOCKED Checked out
(1) Block tires opposite the axle to be tested to pre- vent the vehicle from rolling.
(2) Place transfer case in 4WD Low and automan- tic transmission in Park (1st gear if manual trans- mission).
(3) Raise both wheels of the axle to be tested off the ground.
(4) Turn ignition to the ON position and dash switch to the ON position.
(5) Try to rotate one tire by hand. You should not be able to rotate the tire.

I also switched the air lines on the lockers.
So the rear locker and pump is fine, but the dash light keeps blinking.

So I have to do a little electrical diagnostics now. It's got to be the INDICATOR SWITCH or it's plugs. I need a new battery for my tester so that hosed me today and since I had already done a bunch of stuff, I called it a day. Since the locker actual works, it's also a matter of how much I really care. LOLOLOLOL. If I had ARB lockers, I would not have an indicator on the dash.
One of the great things about being me and having an airock, is that I can put it on all up and just walk under the jeep.
:ROFLMAO:

I'll post pics when the first person replies what the Elff Mod is.
(y)
 

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Sounds like the switch in the locker, I think the PCM is looking for a ground - check that in the FSM.
 

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2004 AiRubicon
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Discussion Starter · #20 ·
Yea, I saw that in another thread but couldn't find any good pictures of what to look for once I have the rear diff cover off. As such, I was going to verify the wiring going to the connector as well as coming out from the Diff first.
Apparently this part is right behind the fill plug. I did try to back that out a couple of turns to see if that helped as I read that elsewhere.

This is from Chapter 3 page 63 in the FSM

LOCKER INDICATOR SWITCH
(1) Turn ignition switch off.
(2) Disconnect locker indicator switch harness (Fig. 27) from the differential housing.
(3) Measure electrical continuity across the switch terminals. Circuit should be closed (zero resistance).
NOTE: If circuit is not closed remove differential and replace locker indicator switch.
 

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