I cheated, and this is what happened

So, after wheeling the taco a few times out in the hills, I couldn't help but notice the few older Jeep XJs I would cross here and there. I never paid much attention to these SUVs before, and I've never owned a Jeep before.

However, something about them was very appealing to me, the boxy look, the simple design, and the "smaller-sized walk-on athlete that makes it to the pros" attitude they carried had me hooked.

So I found a "good deal" on eBay and had it shipped in:



"Stock"


Unsure where to start, I figured I'd replace the leaky washer pumps


Updated radio with bluetooth was next:

Speakers don't work. Why? Because the 20 yr old wiring in the door jam cracked:

And we get new speakers


Also, not pictured, but replaced both front driver's and passenger's door switches.


Next, the 4.0 was leaking at the rear main seal (notorious for these motors). So I ripped the oil pan out and replaced rear-main seal, new pan gasket. Not a drop has leaked since.


Also checked engine bearings. They're solid.

Ripped out the front axle to install new gears, locker and the lift kit. Had an absolute miserable time with every single bolt (which was a theme on this truck). I realized why I got such a "great dealt", being a north-eastern Jeep, it is a "rust bucket". Thankfully, the previous/original owner did a good job of minimizing it. But damn, EVERY BOLT had to be surgically removed.



Called a local shop to get a quote on sand-blasting the rust off the axles. They want $150 for each. I told them to kick rocks and went to Harbor Freight for some wire-wheels:



Primered:


About to check the pattern:



Mostly finished front axle. All new parts:


Next was the area of greatest anxiety for me: ripping out the rear leaf bolts. Notorious for being rusted in and stuck, I knew this would be a sure issue for me. Known to break and leave you screwed needing to do some serious welding jobs, I had to be super careful in removing them. The "nut" is inside and part of the frame. Only the bolt is accessible (front the front eyelets).

PB blasted for a week and then took a torch on game day. Bolt laughed at the impact wrench. Had to go old-school. Nice and slow:


Counting my lucky stars for the day:



Ripped out the rear 8.25. Cleaned it and prepped for new gears. All original gears (front and rear) were in perfect condition. Stock was 3.55. I went with 4.56 (33s)


Replaced EVERYTHING break related. New lines, new pads, new rotors, upgraded the rear to discs....


New brake lines


Got top of the line Koyos everywhere except the wheel bearings. Quickly realized what cheap quality gets you. Shattered instantly while inserting. Amazon'ed Koyos the next day.



Went to install the winch bumper, but it shares the same bolt as the steering box... So went to remove the steering box and the bolts broke in the brace.... went to remove the brace, and the power steering lines busted the pump....

So along with the new bumper, we got new heavy duty steering box.... new heavy duty power steering pump


Having enough of this project, took a time out and went to celebrate Pride day with the misses for her birthday:


Back to work:

ripped out the transfer case to install new yokes.



New driveshaft from Adam's Driveshaft. This thing is gangster!



Inside was in excellent shape. Chain was solid and all bearings were good.
Installed new headliner:
Picked up the 33 STT Pros:


Paid the kids to clean the interior:


Somewhat of a finished product, 4.5 RE lift, 4.56 Nitro gears, front and rear lockers, 33" Coopers and many other various upgrades. (always more to do)




I'll try to add more in-prog photos later. This this is VERY fun to drive.

kinda feel guilty for cheating on the Taco, but hey, I've always been a whore.

 

Very cool build

 

Wow, nice! Love the xj/4.0.

 

Nice truck!

 

I've had two XJs over the years and they were a blast!

Here's a question for you though: why didn't you go with a beefier rear axle for this instead of working on the original? The Dana 30 front is OK for 33s if you upgrade it but I'd have looked into an 8.8/44/9" for the rear of I was going to spend the money on a regear anyway. Obviously the 44/9" options would take more fab work...but the 95+ 8.8s have disc brakes for the cost of some wheel spacers and shock mounts and spring perch relocations.

 

It's my first Jeep, but I haven't read many complaints about the Chrysler 8.25. Seems like a stout axle and pretty comparable to a Dana 44. I've done quite a bit of research.

If/when it gives me trouble I'll consider swapping. Cost isn't a big concern as I did all the work myself in the garage and our wrecking yards are littered with 44s.

The Dana 30 up front is what I'm more suspect about. It's the stock low pinion model. I still fully rebuilt it since it was on hand. Kinda going with the same attitude. If it breaks, I'll deal then and replace as needed.

This is just a toy/hobby (although it's become my DD).

Although any axle/gear can break at any time, if I do snap one of these, I'm hoping it's because I was foolishly asking a small unibody SUV to do too much.

 

Thanks for the entertaining read.

 

I sold my 2000 XJ Classic to buy my Tacoma... you're making me regret that decision.

I ultimately got rid of it when I realized I was spending all my time fixing minor things and buying too many parts. Final straw was when the radiator blew, right before a 3 day weekend, when my wife and I had planned a hiking/backpacking trip.

Miss the ol girl. She was a blast to drive.

 

I hate Jeeps...but damn do I admire and respect the work you're able to do to it. Kudos bro...wish I could do that stuff myself.

 

Looks beautiful. I'm actually thinking about getting a silver colored one. My sister wants one built up now.

I don't know how it is long term as the only daily driver. I can understand the frustration if little things keep breaking here and there. Gets old.

In my case, it's a side kick I'm planning on using as a wheeling rig.

 

Haha. I had no experience with them before this rendezvous. If they were cheaper priced, I suppose i would have considered them. Rubicons here in town are marked $50k+ which is crazy. I got my 2019 TRD cement for $35k and put about $10k more into it. Still less than the Rubi.

I still think the market needs another hardcore competitor to the Wrangler, but that's not likely due to fuel demands.

 

I think they're solid as a DD. Mine was the victim of the previous owner having put low miles on it, but also low maintenance. I bought it in 2015 with 94k miles on it for $6k. I drove it every day for 3 years and only had to fix maintenance issues, aside from the radiator. However, like you, I had the main seal replaced (paid a shop) and I personally had to replace shocks, sway bar bushings, end links, radiator flush (before the blowup), radiator hoses, thermostat, and other minor maintenance. I learned to do a lot of my own maintenance and repairs, as paying a shop would have bled me dry. I came to the realization that once you get over the fear of breaking something, mechanical work isn't so bad. Fortunately, my Heep was rust free, so no broken bolts or stuck fasteners.

Ended up selling it private party for $5500, in less than 24 hrs with 135k miles. Should have asked for more, as I had people begging to sell it to them.

 

Hey OP, I was digging through some of my computer files and ran across this document. Not sure it will be any use to you, as you seem like you know WAY more about what you're doing than I did. Regardless, this is a service manual for a 2000 Jeep XJ.

https://www.dropbox.com/sh/ry2daocqlcxo8nc/AACZogGr0Br2Li2wEJDKqUdxa?dl=0

 

Very cool.
Just recently found myself in a newish JLU Rubicon. (Traded my Challenger 392 in)
1st jeep as a 2nd vehicle since my CJ7 back in the late 80's.

Always liked to have an XJ for a d's though.

 

Wow. This is a great resource. Thanks!

 

Yeep. So far I love it. Can't wait to take it out wheeling for the first time.

I can see myself getting a new JL in the future. I'd also consider a new 4runner with a SAS

 

I "retired" my 92 XJ when she hit 301,000 miles, and bought the Tacoma to repalce it as a daily driver.

Think it is time to start Project Phoenix and get her fixed up as a dedicated trail rig... but not sure my wallet can handle TWO vehicles undergoing Mods

 

Alrighty fellas, Round 2:

So, I was making some adjustments to the A/C compressor clutch, and I noticed a leak in the radiator. Didn't surprise me. It was old. So, had to replace that. While you're at it, might as well replace the thermostat, thermostat housing, turns into a new water pump, new high performance silicon hoses and many other mods.

Ended up going all electric fan and ditched the old-school mechanical fan.

First things first though, 500 mile gear break-in flush. Look at these teeth:


Check out the fluid remnants...:



So here's the new aluminum (Chinese??) radiator with triple fan:



Rad bolted right up for the most part, now installing the fan+shroud. I already removed the mechanical fan (and doing so gained me 500 hp!)



Somewhat put together:


Notice something different with my electrical setup? Yeep. Upgraded to these gangster electrical/battery cables. Replaced all those shoestrings that Chrysler shipped with:



Now we need a more powerful alternator to help power those fans and that bad ass 10K winch up front. Turns out Chrysler likes to share. The Durango alternator puts out twice the power and almost lines up perfectly:


I just had to modify the alternator bracket slightly:

(before)


(after)


Ok, back to the cooling system now. Well, the electric fans power on at 200F (which this Jeep has NO problem reaching) and then shut down at 185F. But where to put the sensor? There are options, but there is no better place to get an accurate reading of engine (water) temp than right as it's exiting the block. After all, that's what OEM does.

So I ordered a new thermostat housing and tapped a hole for the sensor:








Installed new water pump. I use gasket maker on almost everything.



Tire pressure is all set, time to take it for a drive:


Week later, gremlins paid a visit and decided to break my fuel pump. Only took me about three hours to replace. Absolute misery.


If you ever want to know how to get an annoying family member or neighbor to never come around again, just have them help you replace a fuel pump in a 20 year old car.


Alright, so we're under the hood, what the hell. Let's replace those plugs.



Dug up my old gapper. This thing is from the 90s!


These damn motors. Check out the "gap" on this plug. How the engine didn't knock or throw a code is beyond me:


The transmission was running a bit warmer than I'd like. Specially since this is going to be used for wheeling. So, time for a transmission service. Yuck, these jobs are usually very messy.



This pic was AFTER I spent 2 hours cleaning the RTV left behind from the last fella. Guess they are really generous with RTV back east. I was pissed off so I decided to do standard rubber gasket this time:


(be sure to clean and put the magnets back!)

Just to be sure I keep a cool tranny, I installed a cooler. Guess these are used on RVs and towing vehicles. They can easily be added to just about any automatic vehicle. The hardest part was making the mounting brackets.



Of course, just like a credit score, the trans temp is only useful if you actually know what it is. So I installed a GlowShift gauge and I installed the sensor to the line coming directly out of the transmission, as to give the most accurate reading of what's in there (just like the engine above):



Right within range of what Aisin-Warner says.

 

Nice looking build


@hoverlover

 

Nice XJ build you’ve got going on in here!



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