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Check the routing of the vent hose from your front diff. Make sure it's not interfering with the pressure hose when the driver side front suspension is extended. There may be a diagram somewhere showing the "correct" routing for that hose, but I'm not sure where ... All those hoses seem to...

The radio that I put in recently is still working fine. So, you're correct, it was definitely something internal to the first two radios that I tried. The first two behaved identically, so that threw me off for quite a while and made me hesitant to try a third -- but that was the charm, as...

Problem resolved! Another 2002 KJ Limited (same year, trim, and color as mine) showed up at my local salvage yard last week, so I went out and pulled the radio. This is the third one I've tried. And with this one, the display works correctly. It lights up immediately with key turned to RUN...

Thanks for the additional info! - The radio turning on quicker as ambient temp increases might point to a failing solder connection internal to the radio. I just disassembled one of mine (the P05091606AD unit) and am now hunting for the components related to the display. Also, I've identified...

Since this was a long weekend, I decided to do more troubleshooting on this problem, taking to heart Bill's suggestion regarding grounding. With this in mind, I pored through the '02 KJ service manual to find out all I could about wire colors on the radio connector, ground and splice locations...

I agree it's unlikely to be something internal to the radio, since both units I have behave the same way. I recently replaced the ignition switch and actuator assembly with brand new parts, thinking maybe the contacts inside the switch had gotten a bit flaky over time, since the Jeep has...

Hey, did you ever figure out what was causing the problem with your radio? Mine does the same thing. I have the single CD/tape version of the factory radio in my 02 Limited, and don't have an external changer. My radio display doesn't come on when I first turn the key to either ACC or RUN, but...

Hi Tom, I did the pinch weld mod after reading about it here. That metal was thicker than I expected but my trusty Wilton hammer got 'er done. After the soreness in my arm dissipated (aided by a beer) I covered the bare metal area with black silicone. Next I'm considering flush-cutting those...

Thanks for the links, and the tip about the rear diff ... My build sheet says "anti-spin differential", is that another term for Trac-Loc?

Last July I rescued this little beauty from the jaws of the crusher at my local wrecking yard. Drove it home! This is an '02 with a Rusty's lift and American Racing alloys. 255/70/16 Toyo ATs, a bit too large for the wheel wells but I'm making them work. It's my fourth Jeep, but first KJ...