fandroid

Hi all! I'm in the market for an XJ and was wondering what years I should look at and more importantly not look at. I know the 2000 and 2001 models had overheating problems but is there a way to fix that semi easily? Also I read that the 1997s had three different wiring harnesses and that they finally got it right with the last batch before 98, is that true? I'm looking for a 91-99, possibly 01 if the overheating issue can be worked out.

Also how bad is the Dana 35 really? I want to put at least 31s on whatever I get and drive her as my daily driver while only hitting the trails just every now and then. Nothing too mayor. Also I'd like around a 3.5 lift too, I also read some of the late model ones require a sye for some lifts. How true is that and when would that be needed?

Any general information would be greatly appreciated.

Thanks.

jake92

Welcome to the forum!

a few members will be able to tell you about the newer XJs but I have a 92 and I don't have any issues for 310,000 miles. I've heard it's easier to mod with the lack of OBD-II which makes things more difficult. Also, I've seen XJs around my year made to accommodate the newer body style grille/ front end.

Everyone's got there own opinion, but find one that you like

fandroid

Thanks for the response man.

I had a 91 a few months ago (thats why my account is so old, I never got around to making a post lol) and loved it but ended up trading it for a mustang. Now I want my XJ back lol. I like the looks of the 97+ ones just a bit better but the earlier ones can look just as nice with a few modifications. And like you said, you can pull the entire front clip off the new ones and put it on the olds ones so it'll look almost identical. Plus I really like the fact that the pre 95s don't have to comply with the state smog laws and inspection is as easy as "does it run?".

My main concern is the Dana 35s that came on a lot of them. Some people make it out to sound like its the worst thing ever while some say its perfectly fine.

jake92

No problem, personally I liked the newer body style but since I've owned my 92 I love this style. It's also fairly basic which I like.

fandroid

Well I find a guy with a 96 XJ that I am going to meet with friday and possibly buy.

My one question for you guys is this, what are the differences from the 91-95 XJs and the 96? I know there won't be too much of a difference but I figured I'd ask lol. I also know that in 96 the slip yolk was external from that year on, what are the advantages/disadvantages to slashing the internal?

Thanks

Bustedback

The 96 is OBDII, has a stronger lower end than earlier 4.0's because it has a main bearing girdle, the cylinder head is slightly different in port size,, the front axle ujoints are stronger than earlier models, and the power steering bracket is different making belt adjustment easier. 96 is my favorite year for the "old" body style XJ.

fandroid

Thanks for the quick response man!

I've never owned an OBDII car, and that's kinda been on purpose lol. Thats the only reason I didn't quite want a 96 but it sounds like a good truck and its an even better price so I decided I'd go with it.

Oh and does the head flow better or is it just a bit different?

Radi

I have a '96- it's been a good XJ, very little trouble. But there are parts that are '96 only and no longer available new anywhere.
Fuel pressure regulator is perhaps the most worrisome non-available part.
Fuel rail and injectors are also specific to the '96 (but there are others that will work) PDC is different than other years (rarely goes bad though, and there are workarounds)
there are some other oddities that I forget.. I believe the PCM is a one-year item as well.
There is a lifetime recall on the cat if you still have the bad OEM unit. If it rattles when you kick it, it's shot.
The OBDII, despite being a first-year implementation doesn't cause any trouble. It does what it should do without much drama.

fandroid

Thanks Radi, that's exactly the kind of information I was looking for. But what is a pdc?

salad

Power Distribution Center, main fuses and relays.

Personally, I'd avoid 96 for the reasons Radi listed. They seem to have been built with different parts month-to-month and have specific/obscure stuff on them. Any XJ that is taken care of will treat you right. (hard part is finding one) Engine-wise I think only the Renix and Chrysler 4.0s have any appreciable difference. Numbers changed slightly for marketing and emissions reasons but I don't think most people can really tell them apart.

The 2000+ models are prone to cracking heads when overheated. If they do, coolant makes it into the engine and eats the bearings. Given a responsible owner from day 1 this is pretty much a non-issue. Unfortunately most people's idea of cooling system maintenance is "does the air conditioning work?". At best top up fluids then drive it til its broke.

D35 a non issue for 31s with some trail-riding.

fandroid

When you said PDC, main fuses and relays were you saying they are different yhan pre 96s or that they are one year parts as well?

Also if your fpr goes bad in a 96 do I literally have to go to a u-pull and find one because they don't make it for 96 anymore?

One of the main reasons I like the 96 I'm going to look at is because its got to be the cleanest jeep on Craigslist right now. Most other ones are beat all to hell and are basicly just the owners dedicated trail rig that he does want anymore. I don't want a few sensors to stand in my way of a nice jeep but if I have to skip it and hold out for something of a better year maybe I'll have to do that. But I really don't wanna lol.

Thanks again guys

Radi

The PDC (Power Distribution Center)- the big fuse box under the hood is different for '96 than years before or after. It isn't a huge deal as they rarely have issues, and you could swap in one from a different year if you had to provided you can re-arrange some wiring.

The FPR is a bigger issue. They were never manufactured by the aftermarket. The only source was OEM NOS from Chrysler, although sometimes they were re-branded. When those dried up that was it.
Scrapyard is one place to look, provided you can find a '96 with a good one. They'll probably become harder and harder to find.
On the other hand, I still have the OEM unit in mine, no problems 230K+ miles- so it may not be a high-failure part either.
The other option is to convert to a 97+ fuel arrangement, but you have to swap everything from the fuel rail on back as I understand it.

fandroid

Okay, I get what you're saying about the PDC now. But with the FPR, not that I am doubting what you are saying or anything but what is this?

http://www.jcwhitney.com/1987-1996-j...jcwx?year=1996

And this..
http://shop.advanceautoparts.com/buy...rt-23020p.html

Are those not the right part or...? Like I said, I am not doubting you. I trust that you probably know more than me about the vehicle you own lol.

Radi

Those were installed in a few very early '96 models. Most parts houses think that part fits all '96 models, but it doesn't. That is the old-style regulator that uses a return line.
Look at your fuel rail towards the front, if you have the early style FPR like in those links- you'll see it there.
Chances are you don't have it, meaning you have the "96 FPR that's part of the pump assembly back in the tank.

You'll run into this stuff with a '96 since it was a fairly significant change-over year- parts manuals telling you a certain part fits your year when it doesn't. Best to study the old part and compare so they don't sell you the wrong one.

fandroid

Ohh okay I gotcha. Thanks for the help man, I really appreciate it. And I don't own it yet, I am going to look at it Friday and possibly take it home. I really don't like the fact that some parts are hard to come by..