Constantine

Was going to continue my old thread but... new Jeep, new thread I recon.
So we have here a 1994 red 4 door XJ 2wd, auto trans, 4.0.
157,xxx miles, no ABS, 8.25 rear axle with 3.55 gears.

Story....
I picked her up cheap with plans to transplant the engine into my '91.
The previous owner sent me this picture of her in response to a CL ad I was running.



Was said to have a bad wiring harness but ran good before whatever happened, happened to it.
Was about 10 miles down the road so I had to go check it out.
At first glance, someone had tried to fix it, all wiring harness althoughout the inside and under the hood was exposed and most of the interior was stripped.
Looking around under the hood, someone had unloaded the parts cannon trying to fix it.
We negotiated a price since it did only have 157k on it and engine vitals checked out good.

Put my own stock wheels/tires on it and took it back to my shop. Don't worry, no pic of that.


It's just my nature to figure out what happened to something, can't help myself.
Took a little help from fellow members here and another forum to figure out why every single engine management sensor was throwing a code.
Basically, the 02 sensor wiring shorted out from the + heater circut to the - pcm wire and burned up the part of the pcm that grounds the sensors.
So I grounded the sensors to the body and did a little more trouble shooting and she was back in business.
She runs great, even has working A/C.
Seemed to be mechanically sound.
I was hoping I could get it figured out since it was in so much better shape than my old camo junker.
So this is where the swapping and build begins.


That's her just before surgery beside the trans/t-case donor.
Will add more later, currently have it drivable again as a 4x4 5 speed.

The immediate plan:
1st) finalize all electrical and loose ends on manual swap.

●5.0" even of Lift.**
Currently have
-from '91, LCA'S, going to install heim ends in them
-new, RE CAD brackets
-from '91, RE 1660 trackbar, 1665 bracket, 1670 brace.
-ZJ pitman arm
-from '91, Superlift 550 coils
-from '91, skyjacker full set of white bodies 18/30.5" front,
16.5/29" rear
-new, full set of stainless brake lines for 6.5" lift.
-new, daystar front/rear extended bumpstops, 3" lower front
bumpstop.
- new, sway bar disco's.
-new, HD Tierod.
-from '91, shackle relocators.
-from '91, skyjacker 6" shackles.

Need:
-UCA's
-real steering setup
-leafs**
Either IRO or OME 3.5" lift leafs.
●33x10.50r15 Dick Cepek Extreme Country's & procomp 7031's.
- currently have 33x13.50 Interco Super Swamper LTB's on
Streetlock wheels.
Had planned to use 285/75r16 tires and 16x8's but the common
Backspacing is 4.5" for 16's.

●Install my bumper and Warn 9500# winch.
Dirt cheap offroad hidden winch bumper

●Offroad Rear bumper**
Don't have one but am on the fence about whether or not it will
have a tire carrier which will depend on which leafs I choose.

●frame stiffners
Me no have, not sure who's to get

●front diff cover and other protection odds & ends.

●rear shock mounts up higher on axle, looking at the Zone kit.

●some decent audio & sound imaging.
Seriously into good SQ systems that are a little bass heavy.
Will probably be last but it's coming.

Once I get done with this stuff, list will be refilled with more serious upgrades.

5-Speed

Not just 2wd to 4wd but auto to manual as well!? You have got a nice project cut out there. Will be following since i am doing the 2-4wd swap as well.

Constantine

Man, the 4wd swap is only replacing parts.
It is super easy.
How are you planning to convert to a 4wd trans and transfer case?
Have the donor vehicle or buying things here and there?

The hardest part IMO is changing out the pedal buckets and installing the master cyl. which also took the most hours for me to do.
But you're already a 5 speed so you won't have to.

5-Speed

Nope no donor vehicle for me. I didn't want to put any old used drive-train parts back on. So I got a rebuilt trans and transfer case. Then I just sourced out all the other small parts like the shifter and linkage. Those parts I went with used ones. I am pretty sure I have everything needed to do the swap at this point. Like you said, its just swapping out parts and should be pretty easy.

Constantine

Nice.
I wanted to keep it as an auto but the same idea of buying used kept me from it.
Would've had a couple grand in the trans and t-case if I had a used one rebuilt.
Yep, Even the t-case shifter hole is there with a bolt on cover over it.
I installed boostwerks linkage on mine, made the adjustment easy as well.
My original 4x4 always had shiftting issues in either 4 lo or 2wd... just depended on which way you adjusted it.

5-Speed

Yep I know what you mean. The trans was the most expensive part so far. Could have bought another Jeep for the same price as the trans. But IMO, well worth it for piece of mind.

I did see the t-case hole in the floor when I did the carpet. I was really hoping I wouldn't have to cut the hole! I haven't dropped the shifter in yet but hoping it works out fine. If it doesn't, I will probably do the same linkage as you. I might be swapping trans this weekend so we will see.

Constantine

I work 12 hour swing shift and am currently working night shift, which is when I usually get some good work done on my XJ.
But it was 16°F when I got off this morning so I didn't really want to work on it.
I suck at taking progress pics but here is the last tidbit o progress I made.











Ok, so I installed the AX-15 which I hit a bumpstop doing so, the input shaft was smaller in the '91 than the '92-'06 input shaft (just the way it always goes for me).
Ended up having to purchase a Novak conversions adapter pilot bushing which set me back $48 bux!
The rest was easy, new LUK Rep set for the clutch and internal slave kit.
Resurfaced flywheel, cleaned everything on the back side of the engine up and checked the freeze plug while I was back there.
Swapped starters, which idk if that was necessary but I had it so why not.
Still haven't figured out the reverse lighting but have neutral safety switch bypassed so I can drive it in the meantime.
Also don't have the part time light for the T-case figured out.
Haven't had much time to put into that either so maybe in the future to come.

Installed the master cylinder and swapped the pedal buckets out, have everything functional there, that was also the hardest and most time consuming part of the whole project.

Am pleased at how the shifters fit like it came as a 5 speed and 4x4, can't tell that it wasn't in my opinion.
Don't have a T-case shifter bezel atm, maybe I'll find one at a wrecking yard when I go after all the other interior tidbits that the PO lost somehow.
Considering trying to use my 2 door headliner in it, not sure if they are any different... anyone happen to know???

I purchased a wrecking yard axle which set me back $225 and installed it, was pleased that it functioned without any issues upon test driving it.
Once it's more streetworthy, I will put some more miles on it and then break it open to inspect.
They put paint on the diff cover bolts and said if something was wrong with it I could swap it out as long as the paint wasn't broken.

So anyway, the manual and 4x4 swap was successful, have some 3" spacers on the front for now, going to add my BPE'S to the shocks.
Will eventually get around to installing my full suspension system with new coils, appropriate shocks and such.

Drove it around the yard some, can already tell a difference with the lower gearing.
The manual trans model came with 3.07 gears, I kept the 3.55 rear axle and bought the used front axle with 3.55 gears to match.
It's nearly a 0.50 difference for me.

Besides all dat, I started banding the harness back up and ordered some 1.25" split loom to wrap it in.

Constantine

Also installed the Rubicon express 2.5" full length Add-a-leaf which actually extends from spring eye to spring eye.
Factory leafs still had a fair amount of arch to them so they should last a little while, basically has another main leaf now.
Installed new u bolts and put my spring plates with the bump stop shelf on at the same time.
Was going to put my BPE'S on the shocks but that would have given me about .5" uptravel.
So I bought some $20 red body gabriel shocks from Autozone for an MJ which doesn't have a bar pin so still have to use the BPE'S.
Will gain around 4.5 of overall shock length though.







I expect around .75-1" of settling after I get them broke in decent which should match the front after I install my bumper, hopefully in the morning.
Need go edit my main post to include "the plan" last, I just did an AAL because I haven't fully made my mind up on rear tire carrier or not yet.
Basically down to the choice of IRO 3.5" springs w/o it or OME 3.5" springs with it.....

Misc. Parts ordered:
Fan clutch, belt, idler pulley; will inspect everything on belt drive.
Fan shroud for same fan, it and all hardware items are gone ?
Sparkplugs, plug wires.
Dr. Side rear door handle.
Headlight harness upgrade, headlamps & H4 bulbs.
Parking lamps.
Radio install parts.
D30 axle vent tube and some hose to redo all vents to firewall.

Constantine

So, the F@$&£&* upper steering box bolt won't thread in so didn't get to adjust the placement fully but, it is on there good enough for pics!
This is the Dirt Cheap Offroad bumper found on Ebay.
Got a good deal on it, I think I may have bought the first one from them.
There was no other bumper of any type available for the price, but I actually bought it bc it was as close to what I was wanting that I could find already made.

Anway, here it is.
I like it, just wish I'd have gotten the bull bar instead of the stinger so I could have added a 20" light bar to it without it looking too bad.
Considering a possible fair lead light mount to mount it....









Atleast the stinger is small enough that it doesn't obstruct my view.

The fender and flare trim isn't permanent, I just couldn't locate my masking tape so I left some room to straighten it later.

5-Speed

So jealous you are 4wd already! Good progress. And I like the bumper.

Constantine

Thanks, I like it too.
I've had it since like last June to go on my old Jeep but didn't bother to put it on since I needed to replace the engine.
Was excited to finally put it on something .

Jealous? I believe you're the ultimate victor here with thay clean a** '99 model.

Constantine

Mo' progress.
Let's see, have a pretty good buzz going but I'll try to 'member what I did.
Um...
First I ... I removed the rear shocks and compared them to my stockers.
The factory were 20" and the cheapy MJ gabriels + BPE's were 23.75".
Once removed, I removed the rear sway bar, then replaced the brake hose with a stainless braided unit.
Then installed the new shocks.
Replaced front/rear diff juice.
Replaced T-case juice....
Re routed the 02 sensor wiring so that it was no where near the manifold.
Oh, figured out that my steering box spacer didn't fit, hole spacing was off, so that was a waste of my money.
Had to tap steering box threads out and used the stock spacer, went right together.
Enough thinking.
Here's some pics.

Constantine

Constantine

Continuing on with getting the interior buttoned back up.
This isn't a daily driver or show rig but I just can't accept certain things.
The '91 had the clock to the right of the instrument panel and the '94 apparently didn't.
There isn't any wiring in the area for it.
Considering making a switch panel to fill the void.
Put my trusty old Sony CDX-3000 in.

Figured out the 2-door headliner board is the same as the 4-door.
Going to have the areas around front and rear seats & headiner finished just so it's more appealing to the eye.
In the cargo area, I'm thinking of some dynamatted aluminum panels on the sides and maybe rear hatch since I don't have a good cover out of the two.
And the side panels appear to be different.
That's written in pencil though.
Thinking of using aftermarket front seats instead of swapping my other ones over.

Started tidying things up under the hood as well.
I've alot more crap like this ahead of me.
Oh well, I be cheap and have to deal with what you get fo' cheap.

In other news, I couldn't accept the 3" spacer.
I bought some YJ wrangler front shocks, installed my BPE'S onto them, replaced the lower control arms with mine that have the flex joint, rebuilt the flex joints too.
Replaced the coils with my superlift 550's.
Installed stainless lines and sway bar disco's.
Fixed my axle position, it really looked to have alot of negative camber before setting castor angle.

I may put the RE sway bar on this weekend.

I need to do some brake work and am on the fence ab the WJ upgrade.
Especially Since I am ready to pull the trigger on a steering setup anyway.......

Constantine

Have been extremely busy working dual careers lately.
Although I have made a little progress moving forward.
Very little.

Purchased another steering box spacer.
Purchased B lee UCA's... Still waiting on those.
Purchased center caps and center cap decals.
Put my wheels an tires on when they came in.

Installed IRO boomerang shackles.
Cut front fenders enough to turn and actually, my favorite part, took her for a test drive around the property
Oh sweet victory.

Gonna buy new front coils, probably RE 5.5"
Waiting on the UCAs to get here, will put my CAD brackets on.
Gonna order the Dostech shocks from IRO when I have collapsed length determined.
The skyjackers will get me by till they come in.
Also going to relocate rear lower shock mounts before I order them.
That's the major to do for the time being.