welding in jeep
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Joined: Jan 2009
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Year: 1994
Model: Cherokee
Engine: 4.0L Air Intake and TB Spacer
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
Senior Member
Joined: May 2009
Posts: 747
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
CF Veteran
Joined: Aug 2008
Posts: 6,588
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From: Chico, CA
Year: 1986
Model: Cherokee
Engine: 4.3L with headers and full 3" exhaust system
If by chance no amount of encouragement will keep you from welding the entire floor in then at least take this small piece of advice and "Stitch" weld it. That is to weld a short section of say 1/2" and skip about 6" and weld another short 1/2" and skip another 6" until you have gone all the way around what you are welding. Then go back to that first 1/2" weld and extend it by another 1/2" and go to the next one and complete the circle until you have everything solidly welded. This has the advantage of keeping the heat in any one spot to a minimum thus preventing any metal warpage.
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Joined: May 2009
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
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Joined: May 2008
Posts: 817
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From: Michigan
Year: 1996
Model: Cherokee
Engine: 4.0
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Joined: May 2008
Posts: 817
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From: Michigan
Year: 1996
Model: Cherokee
Engine: 4.0
If you look at the second pic, you can almost count the "factory" spot welds on both frame rails. The floor pan is spot welded in and then the seam is sealed. When I was done It looked just like it comes from the factory, a spot weld about every 2.5 to 3 inches.
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Joined: May 2009
Posts: 747
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
Senior Member

Joined: May 2008
Posts: 817
Likes: 7
From: Michigan
Year: 1996
Model: Cherokee
Engine: 4.0
My cost was around $200,( I think) there getting pretty hard to come by, the pan I got was for a 97 XJ but it would still fit my 96, the seats mount the same. I also have, a full rear floor pan that I havent installed yet. It was NS1 or disconntinued, I picked that up for about $60 bucks.....They price them low to git rid of them.
Senior Member
Joined: May 2009
Posts: 747
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
My cost was around $200,( I think) there getting pretty hard to come by, the pan I got was for a 97 XJ but it would still fit my 96, the seats mount the same. I also have, a full rear floor pan that I havent installed yet. It was NS1 or disconntinued, I picked that up for about $60 bucks.....They price them low to git rid of them.
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Joined: May 2008
Posts: 817
Likes: 7
From: Michigan
Year: 1996
Model: Cherokee
Engine: 4.0
No one will have a pan in stock, and it was not a direct fit. I had to hammer a few spots out but it was very close. I would go to your favorite dealer and see if the can get you one. Chrysler has a TSB out for this repair but they don't list an entire floor pan part number, just in halfs. Warraty time pays 20.0 hours for both sides. so you can double that ....at least!! Mine took about 70 hours start to finish.
You will also need the seat risers for the front of both seats.
You will also need the seat risers for the front of both seats.
Last edited by BLKXJ 96; Jun 11, 2009 at 11:42 PM.
Senior Member
Joined: May 2009
Posts: 747
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From: North Jersey
Year: 1996 XJ Sport 2007 KJ Rubicon
Engine: 242 4.0 Ho, 226 3.7 V6
No one will have a pan in stock, and it was not a direct fit. I had to hammer a few spots out but it was very close. I would go to your favorite dealer and see if the can get you one. Chrysler has a TSB out for this repair but they don't list an entire floor pan part number, just in halfs. Warranys time pays 20.0 hours for both sides.
You will also need the seat risers for the front of both seats.
You will also need the seat risers for the front of both seats.
You saved my butt! Saved me a lot of time, headaches, and $$. They are listed up on the chrysler replacement part search engine. 90 something to 96 4dr station wagon package with full pan, inner rockers, i believe something with the b pillars, and various underside/ connection stuff for 205-ish according to them. I know my inner rocker is going on my passenger side is going as well. I've stripped the interior before, have the carpet cut and sectioned for easy removal, etc. Just outta curiosity how long did it take you. I understand you are a jeep tech and all, and being a first-timer welder i was trying to ballpark how long it will take.
Renix Super Guru
Joined: Mar 2008
Posts: 24,653
Likes: 19
From: In yourz postez fissin jurr spelinzs
Year: 1990XJ/1989MJ
Model: Comanche
Engine: 4.0L Renix
BLKXJ Do you know if they are also available for MJs? Can you list the part number so the local dealer can order it?


