BimmerJeeper

I bought a 1998 XJ 4.0L Sport.
I want to make it super reliable, and hit all the common stuff that goes wrong ahead of time.

I also learn with every project. I mostly order parts from rockauto.com
Doing it up front is 20% of the cost of breaking down and paying a mechanic.
So, I love spending money on preventative maintenance parts to make a car more reliable, so it's ok if I go a little overboard.

I want a master list that I can slowly work through.
Can you guys add to this list?

Service items

• All fluids: Oil, coolant, differential, transfer case, transmission, power steering, brakes.
• Cooling system: Radiator, cap, water pump, thermostat, all hoses, Fan clutch
• Flush cooling system
• Replace distributor, plugs, wires, coil.
• Clean Throttle body
• Battery
• Battery Cables
• New brakes/rotors.
• New front and rear wipers
• Serpentine belt
• Air filter
• O2 sensor
• Valve Cover Gasket (leak) and 2 PCV valves
• Oil filter adapter (leak)
• 4 new shocks
• Tranny mounts
• Motor mounts
• Seal rust (floorpans, doors, rockers, etc)

Things to inspect

• Replace tires?
• Replace Clockspring? (airbag light, no horn, no cruise control)
• Any burnt out bulbs?
• Check exhaust (muffler and catalytic converter)
• Cracked Exhaust Manifold?
• Any cracked vacuum lines?
• Secure rattling 4WD shifter?
• Driver’s door check pin and bracket (popping door?)
• Fix all windows (motor, bypass lock switch)?
• Flush clogged radiator core?
• Hood Release Cable?
• Replace Rear Liftgate Struts?
• Replace worn suspension (Front Lower Steering Stabilizer, Front SwayBar Bushings and End Links)
• Replace worn U-joints
• Replace worn Wheel bearings
• Squeaky steeering wheel? Lube Steering Column Boot (from inside)

Optional service items before they die on you

• Alternator
• CPS/CKP sensor
• Replace TPS (throttle position sensor)
• Replace IAC/ICV (idle control valve/motor)
  
• Starter
• Fuel pump and filter
• Temperature sending units (2)

Optional upgrades

• Headlight harness upgrade
• New Headlights
• Transmission cooler
• Replace center console
• Replace carpet
• Replace seats

Are any of these totally unnecessary?
Am I missing anything big?

1976Mustang

Jeep and Reliable don't really fit in the same sentence. LOL. I usually get replacement parts from the junkyard.

On the Bulbs, i would convert all of your lights to LEDs. That's what I'm doing right now, so i don't have to worry about them burning out. They're super cheap on ebay.

Remember their may be TWO thermostats, one on the front of the engine and one on the back for the gauge

PNWjeeper

For the cooling you might want to think about replacing the clutch fan with a new one (either an upgraded ZJ clutch or just a replacement) or a second electrical fan. If you do stay with the clutch fan make sure you have the cowl that goes around it otherwise you lose most of the fans cooling power.

Rockville

The only engine with 2 thermostats is V12 Jaguar. Is that what you are talking about?

NorCalJeep

I think you have a complete list. Nothing I would add.

srb531

driveshafts & front axle shaft u joints, front wheel bearings, add a tranny cooler if its a auto trans. i bought a 98 w/ 130 k miles recently & have been working thru a similar list.

weld3z

1-spark plugs (check the coils)
2-oil change (check transmission and deff oil)
3-engine belt
4-tyers and tyre alignment
5-check brakes
6-allighnment
7-all fuses check
8-flush radiator
9- its the most important thing in my opinion Cleaning IAC and Throttle body.

dont change something well work for years like Battery,O2 sensors,Starter or Alternator also no need to change air filter just clean it

djb383

Not to sure about having 2 t-stats?????? '96 down have 2 coolant temp sensors/sending units (1 in back of head and 1 in t-stat cover), '97 up only have 1 coolant temp sensor in the one t-stat cover. LOL Fenders, doors, hoods, etc. from the JY are fine but don't use/trust any JY cooling system items and expect to have a reliable DD.

1976Mustang

I used the wrong wording there. There's one t-stat, but two Temp Sending Units. My bad lol.

djb383

'96 down have 2 (sending units), '97 up have 1.

1976Mustang

He said 96-00, my argument is still valid :P

BimmerJeeper

Should you replace both temp sending units?

BimmerJeeper

What about treating rust? Is it worth renting a sandblaster and then just sealing it with some sort of black "tar" like substance? This seems like a $100 band-aid that could add years to the unibody. Is there a thread about this?

1976Mustang

I would, since you're redoing the cooling system anyways.

salad

You can rent sand blasters? Hm cool. Underside rust is a HUGE problem. Whenever I see these AZ, NM, TX or Southern CA XJs I get very angry haha. Aside from cutting out rot and replacing, best results can be had with removing surface rust however possible, slapping some rust inhibiting primer and paint on it (POR-15 looks like fun), and then armoring the bottom with bedliner or a rubberized undercoating to prevent any damage to your solution. Then, anywhere else should be oil sprayed. Up here we have Rust Check and Krown as the two major brands... I'm talking about stuff like inside body panels, pillars, inside the frame rails, etc. Places you can't wire wheel or paint.

As for things to spend money one... well... is space and time an issue to? Many times I've thought about just completely disassembling my Jeep and putting it back together but I don't have resources to do that.