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Discussion Starter #1
Hi all, thought i would do a resurrection thread to lighten things up a bit amongst the broken things.

My wife and I have a 2006 Limited which we love, but It's gotten pretty rotten underneath. Two weeks ago I found a rust free 2007 Overland in CT. Like everything i buy it needs some work, appears to have been repo'ed at some point, I bought for the right price and was able to look it over on a lift before trailering it home.

When i looked it over, I found that some things were recently replaced (shocks, rear stabilizer bushings, brakes).. It appeared to have been detailed but smelled like a wet dog. Runs and drives great. Only real issue besides the dog smell was a couple missing cosmetic parts and the dreaded dome lights/doors not working fuse 12 circuit issue.

Plans;
Get everything serviced and running right (all fluid/filters, spark plugs, O2 sensors)
Fix the electrical issue in the cab
Undercoat to rust proof as much as possible
AFE air intake, MBRP cat back exhaust
Swap rims and tires from the '06, possible 2" lift if tires don't fit.
Prep '06 for sale


Project #1
First thing i found when i got it home was mouse droppings in the headliner, I figured that they chewed a wire to cause the door circuit issue so i pulled the headliner, inspected and Ohm'ed the harness. All looks well and wiring diagnostics continues. Inspected the door harnesses to find they look great, previous repair had been done to the drivers door harness. With both door harnesses and the rear green connector unplugged, system voltage to the doors is 3v. Under the dash i have 12v on the same wire, and ground picks up to 5v. Seems like a short in the dash somewhere. I removed the drivers side trim to inspect the cab harness and found no issues. Still working on this one, looking for a cab harness diagram so i can figure out where this harness goes. I've been searching the forum and haven't found a fix yet, seems like most were fixed with the door harness or a short in the headliner.

Project #2
Living in Eastern upstate NY, we have fallen in love with the commanders 4x4 system. I need this thing to not rot out on us, so i'm undercoating with a product called rusfre. I've used this about 7 times before on other vehicles and they are doing great after 6+ years in the salty winters.
For prep, I've removed the F+R bumpers, rocker panel covers, and fenders. I then hit anything that is showing signs of rust with a needle scaler and wire wheel, spot sand blast where necessary. Everything is taped off and I'm undercoating Saturday morning. I will likely let it sit for 2 days before reassembly because this stuff stays tacky for a while. Any overspray gets cleaned up with gasoline and a rag so long as it hasn't dried.

Project #3, tune up and upgrades will continue once the undercoat is finished.
 

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Thanks for the thread. It's fun to see I'm not the only one tearing into these things and wanting to keep them alive.


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Discussion Starter #3
Undercoat completed, going to assemble over the next couple days after work. Worst rust spots were the bottom of the fenders, and a couple places where the fender flares rubbed into the paint. Otherwise this thing is in better shape than most 2 year old cars out here.
 

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Undercoat completed, going to assemble over the next couple days after work. Worst rust spots were the bottom of the fenders, and a couple places where the fender flares rubbed into the paint. Otherwise this thing is in better shape than most 2 year old cars out here.
This is something I need to do;

I'll probably try to have it done toward the end of this year; Fortunately, I only have some minor surface rust underneath; My XK has always been covered when not in daily use, either in a locked storage unit or garaged, since I've owned it. That being said, I don't want to continue letting it go unchecked.

Nice work by the way;
 

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Discussion Starter #5
Update, had a couple set backs with a busted front caliper but today I put the 2007 on the road, took the family out for ice cream.
MBRP exhaust installed, really good quality, easy install. A little rumbly at the lower RPM but really not enough to stop you from having a conversation inside. Combined with the AFE power intake the Hemi really woke up from previous test drives. Averaged 17-18 mpg on our mostly 55mph test drive so im pretty pumped.
Found the repair manual on here, going to get this wiring issue fixed so i can use the front windows.
Next up will be reinstalling the rocker panel covers and driveshaft swap to our servicable unit.
 

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Discussion Starter #6
Been on the road and running straight for a week now. First day out wound up underneath hitting the starter, since that was replaced all is well.
Wiring issue was a pair of red/white wires beside the drivers seat, the manual was extremely helpful in troubleshooting. The wires were in the center of the harness, had a small nick in both that allowed corrosion to set in. I found it by loosening up the harness, and pulling on the wires to see where they got stretchy ?
Loving the MBRP exhaust, looks nice, good rumble but not too loud.
Also found when the rocker covers came off i busted off all the push in tabs on the top, i used 3M double sided automotive tape, seems to be holding up well.
Only thing missing now is a driver side mud flap, happy car and happy wife! I will have to update after a couple years to show how the undercoat is holding up. I love this rusfre stuff, highly reccommended.
 

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Been on the road and running straight for a week now. First day out wound up underneath hitting the starter, since that was replaced all is well.
Wiring issue was a pair of red/white wires beside the drivers seat, the manual was extremely helpful in troubleshooting. The wires were in the center of the harness, had a small nick in both that allowed corrosion to set in. I found it by loosening up the harness, and pulling on the wires to see where they got stretchy ?
Loving the MBRP exhaust, looks nice, good rumble but not too loud.
Also found when the rocker covers came off i busted off all the push in tabs on the top, i used 3M double sided automotive tape, seems to be holding up well.
Only thing missing now is a driver side mud flap, happy car and happy wife! I will have to update after a couple years to show how the undercoat is holding up. I love this rusfre stuff, highly reccommended.
Awesome stuff! I need to think about doing the undercoating as well. Mine was bought new in Alaska by the previous owner, since then it's only been in warm environments, but there is some light surface rust and things that could grow over the years. Also, not knowing where we could move to next (military). Your undercoat job looks real good and really thorough coverage! That's how you gotta do it to make it worth it, though.
I really like those rims combined with the all black/chrome Overland look!

Always makes me sad seeing a really nice vehicle, especially a top trim-line like the Overland that's basically been left to rot somewhere. Glad you've brought it back to life!!
 

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Looking good, i'm also in New York but towards Northeastern Penn and the rust!! The rust I found today, man.. I'm going to take it in to get it undercoating as I don't have a lift but I already got most of the front end with rust reformer... I'm thinking I may not hit it with any enamel and just go straight to the undercoating with this stuff, coverage looks really good.
 
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