WH & XH How to's Modifications & Repairs
 

This was missing from our section, So if you have a mod you would like to share or a how to repair please post it here.

Try & keep the chit chat to a minimum, use thumbs up to like a post.
I will occasionally delete comments about posts,
Please don't be offended if I delete your comment.

HEMI & CRD Hydraulic Thermo Fan Override
 

Having troubles with High engine temps when towing? That Bull Bar restricting air flow?

This little mod may help.

By running a single wire from the thermo fan wiring through a switch to ground you can manually ramp up the fan RPM to give you extra cooling.
This should work for WJ/WG with the same type of fan assembly.

Here is a basic wiring diagram of what to do
http://www.ausjeepoffroad.com/forum/...1&d=1486372559

There is an electrical connector at the bottom left (passenger side) of the radiator.
http://www.ausjeepoffroad.com/forum/...2&d=1486373170

Solder a single wire onto the Brown & Violet wire (centre wire) then tape it up.
http://www.ausjeepoffroad.com/forum/...3&d=1486373248

Run the wire into the cabin & connect to a single pole switch, I used a "Carling Style" rocker switch rated at 20 amps
http://www.ausjeepoffroad.com/forum/...1&d=1486373869

Connect the wire front the fan to pin 2 (keeps it isolated)
Run a ground wire from any metal point under the dash to pin 3.
Don't use pin 7 to light up the switch, if you want it to light up use a 2 pole switch where the poles are separate.
http://www.ausjeepoffroad.com/forum/...1&d=1486374300

2005 to 2007 Ignition switch (not barrel) replacement
 

Ignition switch (not barrel) replacement
Here is a link on how to remove your ignition switch and replace the electrical part.
http://www.jeepforum.com/forum/f67/e...codes-1291281/

Part Number 04685719AI

http://www.ausjeepoffroad.com/forum/...4&d=1509504519http://www.ausjeepoffroad.com/forum/...1&d=1509504519

The CRD has an extra terminal on the switch and this will cost you an extra $200 or you can do the conversion below.

http://www.ausjeepoffroad.com/forum/...45016f20cf.jpghttp://www.ausjeepoffroad.com/forum/...4508b2f831.jpg

Internally they are identical accept for the top cover that houses the extra contacts.
http://www.ausjeepoffroad.com/forum/...4518c692f0.jpghttp://www.ausjeepoffroad.com/forum/...4518c2e339.jpg

I just removed the top cover & fitted it to the new switch, watch out for the spring loaded ball bearing, it may pop out but its not that hard to refit.

Chirps write-ups
 

Here is a link from a WK (1) owner in the USA.
All credit goes to User Name Chirpz from Jeepforum. He has put a lot of effort into these write-ups. **) Hope you find them useful.
http://www.chirpz.com/jeeps/

NAG1 Oil Leaks and where to find them,
 

Thanks to ren0vator
Check out his Bang Crunch thread for more. http://www.ausjeepoffroad.com/forum/...d.php?t=146223

Three oil leaks on NAG1

1.Rear left of the case there is a park lock mechanism
Two new O'rings into the large bore at the bottom of the photo
O'rings could be accessed after removing valve body, but would be PITA
https://lh3.googleusercontent.com/Ps...H6NVH6iNXTrnOw

2. Dipstick tube
For some reason the new seal is twice the size ???
Right part number, just way too large
That TSB must include a hole saw :p
Reinstalled original rubber grommet with sealant
Could be done without transmission removal
https://lh3.googleusercontent.com/ze...D_jzRIRH1sLmwg

3. Bellhousing Breather
There is a plastic breather on top of the bellhousing
Solid fix would be to tap a thread and install some alloy barbs
I just re-fitted the original plastic barb with a heap of sealant
The plastic breather can only be successfully removed with transmission disassembly
https://lh3.googleusercontent.com/g6...uuwmWHE2wZpdbg

Turbo Intake oil leak fix.
 

http://www.kraftwerk-shop.cc/WebRoot...Stueck_CRD.jpg

These guys (http://www.kraftwerk-shop.cc/epages/.../Products/3130) don't sell to AU
But here I have sourced all the parts locally.

http://www.point-blank.com.au/25-x-1...ece_p_224.html

PDF instructions
http://www.kraftwerk.cc/upload/downl...08ca88e22b.pdf

--------------------------------------------------------------------------------
http://www.point-blank.com.au/thumbn...axx=300&maxy=0 HCT67 2.5" Stainless T-Bolt Hose Clamp (67-75mm) $7.00 x 2 $14.00 (these are a bit bulky, you can use normal hose clamps if you prefer)

--------------------------------------------------------------------------------
http://www.point-blank.com.au/assets...icone/t_51.jpg SILT63 2.5 x 1 Inch ID (63mm x 25mm) T-Piece $21.00

Subtotal: $35.00
Discount: $0.00
Shipping: $10.00
Sales Tax: $0.00
Total: $45.00




Point-Blank Automotive
PO Box 1209
Greythorn, VIC 3104
Phone: (03) 8680 3644
store@point-blank.com.au

I think this will be the next mod. good work clarky.