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Old 07-10-2018, 11:14 PM   #1
rosco11
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Default Lease Ride Upgrade - Jeep Truck

1991 Jeep Comanche

Hola Green Screen! Some of this is backdated a bit but wanted to start a new off season thread.

I've been ready to get started with some work to my "new to me" lease ride. Had to finish up a project on my Sonoma 4x4 and took it back out to the lease and its driving great. So here we go with a probable upgrade!

I've wanted a Comanche since I was a kid cruising around our hunting lease with my brother in our uncle's 4x4 daily driver Comanche.

3 years ago I bought a cheap GMC Sonoma for our hunting ranch and that truck taught me how to weld, rust repair and to start understanding some mechanical work on vehicles. Rust stinks but man that 4.3L engine started everytime. Fast forward to about August 2017, frame rot got the best of her and the steering gear completely broke loose. Brought her home and began working on the fix. In the mean time I knew it was time to upgrade to a jeep truck.

Started a local search for a Comanche and found one on Craigslist in Houston and reached out by phone and email but never heard back from the dealer/owner (to their credit, this was weeks after hurricane Harvey and his business could have been lost, I don't know) So the search expanded and I found my '91 in West Virginia, dealt with the owner, agreed and had it transported back to Houston. Here's what she's working with...
1991 Sportruck 4.0L H.O.
4x4 Automatic
73,000 miles
Short bed
231 transfer case
2" coil spacers
Dana 30 & 35 with 3.55 gears
Bench seat
Vinyl floor mat
Some moderate surface rust

Some issues..
Outer window seals are rotted away, last hard rain had 1/4" of water in both floor boards
Brakes are fairly weak but definitely functional
Power Steering pump is whiney
Possible rust repair needed in floor pans, nervous about pulling the mat up
Shift indicator needle is gone.. I want to replace that for sure
Speedo isn't working
Driver side door sag just a bit
Pillar lights or door jamb switch not working

With that said, this MJ starts and runs awesome. 4x4 engages and works really well. It has so much more pep and acceleration and handling than my Sonoma. The engine is strong and the truck is light!

Future plans..
This will need to handle off road as it will be my primary hunting truck. However, it's in good shape so I'm going to make sure its road ready too. Here are a few plans...

Fix outer window seals.. water in cab is ungood!
Fix the Jeep emblem
Ford 8.8 axle swap, spring over
Regear Dana 30 to 4.10 with a TrueTrac
Add frame stiffeners
Upgraded HD steering
A suspension lift
285/75/16s
Upgraded front bumper
Load sensing valve delete, not hooked up anyway currently
95/96 Cherokee brake booster & MC swap
Possible switch to bucket seats
Possible switch to carpet
Radiant barrier / sound deadening mat of some type
Window tint

Got started with my first project, a complete flush of the power steering, helped some with the whining but didn't completely fix.

This Comanche is awesome already and I'm pumped to make it even more capable for what we need and lots of fun along the way. I hope you all like it and I hope I can reach out with questions and advice. I'm no expert and have spent just as much on tools as the project itself.

Here's "The H.O." it's been given as a trial nickname that might stick or it can earn another.

Pics to follow..

Last edited by rosco11; 07-10-2018 at 11:25 PM.
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Old 07-10-2018, 11:18 PM   #2
rosco11
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Here are some pics...
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Old 07-10-2018, 11:46 PM   #3
Smithwr
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Their worth money unmolested. I think you would be better served to sell it for profit rather than beat it up
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Old 07-10-2018, 11:52 PM   #4
rosco11
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Quote:
Originally Posted by Smithwr View Post
Their worth money unmolested. I think you would be better served to sell it for profit rather than beat it up
The previous owner already made quite a few mods and repairs.. i have an idea of what a truck like this is capable of and a total coolness factor (to me atleast).. gonna work hard on it to make it a keeper.. I've wanted one of these since i was a kiddo.. I'm probably not interested in selling even though they are semi rare and the 1991 and 1992s even more rare.. i think they only made ~1700, 4x4, autos in 1991

Last edited by rosco11; 07-10-2018 at 11:56 PM.
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Old 07-11-2018, 07:57 AM   #5
rosco11
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Wanting to upgrade the Dana 35 axle to be able to handle larger tires and some offroading.. We set out on a search and finally found a donor. Bought a junkyard Ford 8.8 limited slip with 4.10 gears and discs from a '99 Eddie Bauer Explorer

My brother helped me bring it home. Wrapped it up and will keep it on the side of the garage till it's time to dig into it
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Old 07-11-2018, 08:01 AM   #6
MQ32Shooter
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That’ll be a good one to use in Rocksprings!
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Old 07-11-2018, 08:35 AM   #7
rosco11
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Quote:
Originally Posted by MQ32Shooter View Post
Thatíll be a good one to use in Rocksprings!
Heck yeah man.. I'm so fired up! My Sonoma is capable for sure, but I've always wanted a Comanche! Its gonna be a lot of work, i want to make it road ready and very offroad ready! I'll pass on the Sonoma to my dad so he'll have a 4x4 to use and maybe sell it one day.
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Old 07-11-2018, 06:19 PM   #8
hoythunter
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I can't wait to hear your dad complain about you taking over his garage again. If u guys need welding help again on this 1, hit me up. It'll require lots of welding fluid though... ��
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Old 07-11-2018, 06:24 PM   #9
Crazy Horse
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so jealous...
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Old 07-11-2018, 06:30 PM   #10
rosco11
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Quote:
Originally Posted by hoythunter View Post
I can't wait to hear your dad complain about you taking over his garage again. If u guys need welding help again on this 1, hit me up. It'll require lots of welding fluid though... ��
Haha! You nailed it.. he'll probably get funked a bit! But i always clean and organize his garage way better than i find it so maybe that will help! We always have plenty of welding fluid on hand!
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Old 07-11-2018, 06:33 PM   #11
Ryanm
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My buddies brother built this for his company.... Cool example to get excited about!


http://www.fourwheeler.com/events/17...017-tensema17/
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Old 07-11-2018, 06:42 PM   #12
rosco11
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Quote:
Originally Posted by Ryanm View Post
My buddies brother built this for his company.... Cool example to get excited about!


http://www.fourwheeler.com/events/17...017-tensema17/
Yeah man, that's a really cool Manche! I've seen it several times while shopping on JCRs website.. I'll be funding some of their next project with my build spend..lol. they make great stuff and i plan on several items from them!
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Old 07-11-2018, 06:45 PM   #13
rosco11
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Hit a sale a few weeks ago.. pulled the trigger on Mickey Thompson MTZs 285 75 16s with Pro Comp 16" wheels.. I'd been following a few online retailers for tires and I thought based on price I was gonna get the BFG km2s when the right sale hit they were about a hundred less than the Mickey Thompson's, watched these prices each weekend or so for 3 months and then the best sale hit and Mickey Thompson's dropped a deal and I jumped on it.. for our rocky and unforgiving southwest Texas hunting ranch, quality tires are a must.. we've seen many many good all terrains and mudders lay flat when they can't handle the mesquite thorns and cactus. Can't wait to get these mounted up!
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Old 07-11-2018, 06:51 PM   #14
Ryanm
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Quote:
Originally Posted by rosco11 View Post
Yeah man, that's a really cool Manche! I've seen it several times while shopping on JCRs website.. I'll be funding some of their next project with my build spend..lol. they make great stuff and i plan on several items from them!
They make some cool stuff for sure! It's a great place to spend your money. All American made parts. I've known the family most of my life. Literally started in a garage and worked night and day to build the company.
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Old 07-11-2018, 07:14 PM   #15
chicken fried
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Good little truck. That 4.0 is a beast and easy to work on. I had one in a Jeep and I never felt under powered.
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Old 07-12-2018, 06:37 AM   #16
rosco11
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Might need some help here.. does anyone have a windshield guy they could recommend (N Houston)? I just need this one removed and repositioned, i think it's leaking and it's off center.

The windshield trim clips are broken and the trim was half hanging on. I removed it and going to try and get the rest of the clips. I want to add a soft rubber black trim for the later Cherokee.. 95+ I believe.

The original owner must have reinstalled the windshield and set it too low to be able to reinstall new clips. We'll make it work somehow!

Last edited by rosco11; 07-12-2018 at 06:49 AM.
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Old 07-12-2018, 08:45 AM   #17
batmaninja
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This guy has replaced some winders for me, pretty cheap and does a good job.

290 and Antoine area.
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Old 07-12-2018, 09:53 AM   #18
rosco11
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Originally Posted by batmaninja View Post
This guy has replaced some winders for me, pretty cheap and does a good job.

290 and Antoine area.
Very cool.. I'll give him a call!
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Old 07-12-2018, 02:40 PM   #19
rosco11
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Got a little project finished.. my busted beltine window seals got replaced. It was an easy project..I like those! .. and brand new parts!
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Old 07-12-2018, 02:47 PM   #20
Bowtech32
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Man I have not seen one of those in a while
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Old 07-12-2018, 03:54 PM   #21
rosco11
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Man I have not seen one of those in a while
Yes sir, they didn't catch on like the Ranger, Sonoma and S10 did in the marketplace.. they were made for only 6 years.. and eventually semi turned into the dodge dakota. Nonetheless they are fantastic little trucks and 99% of the parts from the cab forward are exactly the same as the jeep Cherokee. They made 3 million jeep cherokees so luckily, junkyard parts are pretty available minus the truckbed, tailgate, tailights and a few other parts.
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Old 07-12-2018, 03:58 PM   #22
Spearchunker
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I had the same truck in high school. Dang thing was tough!
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Old 07-12-2018, 04:26 PM   #23
TexasTealHunter
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I will be subscribing sweetness!
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Old 07-12-2018, 07:00 PM   #24
hoythunter
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If you need a winder feller I'll set you up with my cousin. Cheap & good work, he does all my glass work.
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Old 07-12-2018, 09:51 PM   #25
FLASH_OUTDOORS
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Watching this!!
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Old 07-12-2018, 10:16 PM   #26
rosco11
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Quote:
Originally Posted by hoythunter View Post
If you need a winder feller I'll set you up with my cousin. Cheap & good work, he does all my glass work.
Perfect man.. I'll text you for his info!
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Old 07-13-2018, 05:49 AM   #27
TX03RUBI
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Man I’m jealous! That’ll be a great hunting rig. Good luck sir.
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Old 07-13-2018, 08:33 AM   #28
rosco11
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Man Iím jealous! Thatíll be a great hunting rig. Good luck sir.
Thanks! It's an awesome truck!
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Old 07-14-2018, 07:43 AM   #29
rosco11
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A few weeks ago we did the big reveal!

Bought the Ford 8.8 limited slip axle at the junk yard.. we suspected from the vehicle it came from, but were not sure exactly. Is it the preferred beafy 31 spline or a normal 29 spline axle shaft.. once we take this cover off, we'll find out!?!?
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Old 07-14-2018, 08:15 AM   #30
rosco11
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It's a boy!

31 spline axle shaft.. Saweeeet!
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Old 07-16-2018, 01:07 PM   #31
rosco11
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Bought some brand new 16x8s and unfortunately, at the price point i wanted to stay at, i couldn't find any that were matte black. I roughed up the glossys and gave them a few coats.. Perfect!
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Old 07-19-2018, 12:50 PM   #32
rosco11
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We tackled the first major projects.. In the Texas heat everything about it was a little tougher that day. We removed the bed & removed the holy gas tank. We fought the bed bolts all afternoon, broke the middle two studs and couldn't find the rears. Taking the bed off was supposed to be easy..lol. didn't want to, but we removed the bumper and receiver hitch mounts and Bam.. rear bolts were hidden by the mounts. Got em off, unhooked everything with gas tank, filler hoses, muffler hanger etc and it came right off.
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Old 07-19-2018, 01:03 PM   #33
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Cool truck. Should ride pretty good also.
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Old 07-19-2018, 03:00 PM   #34
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Like the pics

And doing anything in this heat is an accomplishment.
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Old 07-19-2018, 03:40 PM   #35
rosco11
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Cool truck. Should ride pretty good also.
Thanks man! Were gonna try to set up pretty nice!
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Old 07-19-2018, 03:42 PM   #36
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following!
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Old 07-19-2018, 06:34 PM   #37
rosco11
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Like the pics

And doing anything in this heat is an accomplishment.
Thanks hopedale! We tried our best to cool from the inside out with beverages!
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Old 07-19-2018, 07:15 PM   #38
Iamhooked
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Following!
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Old 07-21-2018, 11:50 PM   #39
rosco11
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Got some work done on the Manche. We are doing the load sensing valve delete, disassemble the Ebrakes, remove the drive shaft etc..

We got it almost all the way done, fought with disconnecting the lines from the current prop valve, they were all really tough and in a pretty tight spot. We absolutely mangled one of the flare nuts, so that line will have to be replaced along the way to finish out the project. We used a 3/16 adapter to couple the rear lines together once we removed the valve. I'd offer the valve up for another comanche owner but it is minced rust meat.. no good and unfortunately, will be discarded.

We are replacing the rear ebrake cable for new ones the match up to the ford 8.8 so we removed the existing that didnt work anyway.

We will also be doing a slip yoke eliminator and new drive shaft so we went ahead and disconnected the current.

It was a good project day to have some garage time, beers and working with my brother and hanging with our parents.
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Old 07-22-2018, 08:09 AM   #40
Rubberdown
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Might as well wire brush that frame and paint it while your in there. Looking good!!!!
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Old 07-22-2018, 12:09 PM   #41
rosco11
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Might as well wire brush that frame and paint it while your in there. Looking good!!!!
Thanks bud..Yes sir.. thats the plan!
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Old 07-22-2018, 12:33 PM   #42
rosco11
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We found the remaining master cylinder line from a Cherokee and got it installed and that finishes the load sensing valve delete project!

Then we rolled out into the driveway and pressure washed the junk and gunk off the frame so we can get started with rust prevention.
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Old 07-22-2018, 12:47 PM   #43
locknload
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great project, following...
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Old 07-22-2018, 01:12 PM   #44
rosco11
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great project, following...
Thanks bud! Were gonna put some time and effort into this one.. in no way are we experts and just about every project will be a first
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Old 07-22-2018, 01:16 PM   #45
rosco11
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Just noticed... i was Pimpin the TX Cull Hunters Assoc t-shirt!
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Old 07-22-2018, 02:43 PM   #46
quarterback
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Looking good, keep it up. Seeing you do this motivates me to get back on my old truck project. It's just so freakin' hot right now....and my garage does not have air conditioning.
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Old 07-22-2018, 05:05 PM   #47
rosco11
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Looking good, keep it up. Seeing you do this motivates me to get back on my old truck project. It's just so freakin' hot right now....and my garage does not have air conditioning.
Thanks QB! I hear ya on the no air conditioning.. we're that way too. Ugh! Didn't plan on it being a summer project but we got delayed for a few months getting started. Man, just lay out a plan for that old truck and start chipping away at it!
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Old 07-24-2018, 09:31 PM   #48
rosco11
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A few weeks ago we had a heck of a weekend working on the Comanche! We did so much prep, had snags and issues along the way with equipment or running out of abrasive media and many other things. However we kicked butt on the moderate rust removal and prevention!

We used a 40lb pressure blaster with 2 compressors T'd together, black diamond coal slag media, Texas July heat, humidity and rain is perfect for long sleeves covered by a dust suit and blasting hood. Nnnnt! The hood was terrible so i upgraded to a carhartt heavy shirt wrapped around my head. My brother and i blasted about 80% off and we ran out of media. Total hack job with newbies running the blaster.. self admitted..lol! It worked pretty good though! We brought it back into the garage and continued with an array of wire wheels.

We prepped for paint and had this weird gunk that rose to the surface of the metal, alcohol in a spray bottle and a rag would kinda get it off, i went to grab another spray bottle and found one that had white vinegar in it, i tried that and that gunk just wiped off smooth.. then we're noticed the frame was turning gold.. it was the weirdest thing. I quickly made a spray bottle of baking soda and water and doused it with that to neutralize. Then we hand washed with soap and water and then pressure washed.. it got some of the gold off but it was on there big time so we alcoholed again and started painting.

We used rustoleum pro rusty metal primer. That stuff is awesome! Check out some of the pics below!
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Old 07-25-2018, 06:09 PM   #49
rosco11
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Had some time and put a coat of paint on the rear frame.. even got my mom to jump in and help! Trudie's a painting supa star!
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Old 07-28-2018, 07:31 PM   #50
rosco11
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Got the axle out today, springs and sand blasted and painted the gas tank straps and emergency brake bracket
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