10 years in the making
 

I bought a 1996 Cherokee bone stock model that had only 135k miles on it back in September of 2009. I had recently lost my job but went rock crawling with some friends and I was hooked. I saw an ad for this XJ for $500. It had 31's, an add a leaf lift, faded paint and flaking clear coat, reach across door locks and crank windows, oh and it had nerf bars. It had been sitting for about 6 months because the prev. owner said it had trans issues and wasnt very handy. Aamco said it would cost $2500 to fix. 1 day after my rock crawling trip I had my very own Jeep, my very first Jeep.
I ended up using it a little as it was starting to get hot in Phoenix and the a/c didnt work very well. I used it only when it was cool and ended up changing the plugs, cap and rotor and 6 new plugs. I also changed the oil and filter, water pump, t-stat and radiator. I saw a work up on how to add a trans cooler and did that too. I then cut the fenders and added more lift with some 33's. It was great like that. I took it rock crawling to spots like Payette Draw, Box Canyon, Terminator and desert driving everywhere else. I even took it to the Spook Rally a few times. It wasnt bad ass just bad ass for me and I got to see places I had never before and was with my friends.
Then everyone quit crawling and I was all alone. I joined some local clubs but it wasnt the same. I sat on it in the same condition adding little things here and there. Until recently I met some people who were like me and wanted to see and explore Arizona. We were taking our kids sledding up to 4 Peaks and ran into a big crowded road full of vehicles that couldnt make it up any further. My buddy and his new JL were in tow and we went around everyone. The snow here is like gold, gotta go check it out. Up to 12" at the top and the kids loved it. In meeting my new crew I got re-inspired to work on the XJ and make changes. In the 10 years of owning this Jeep I only put 20k miles on it.
First I had to flush the cooling system a few times and took some suggestions from you guys on this forum. I purchased a new exhaust man as mine is cracked and sending it out to get Jet Hot coated. This coating is supposed to reduce the temps from the exh. manifold significantly. Once I get that installed, I will work on these next items:

gas tank (mine is dented from coming off a rock)
skid plate (probably from the JY)
oil filter mount is leaking so I will get those o rings. I saw a guy who installed a kit on this mount that had a line going to an external oil cooler somewhere in the engine bay and back to the engine. It doesnt leak really bad but enough that I need an oil pan on the driveway, I just use a board.

These next items arent necessarily needed but on a wish list. Any help here would be great.
RC Long arm 4-6" long arm kit
Hack n' tap or SYE - I dont believe the case has ever been opened, should the chain be checked since I have 155k miles now. If it gets opened then I will do the sye
Will I need new drive shafts?
Unibody stiffeners front and middle
upgraded durango steering box
probably going to keep the hp D30 - it has a lunch box locker w/ stock gears. I'd like to make a Super 30 like this . I would do the 4340 axles instead of the cv style and probably add gears with a selectable locker.
now for the 8.25. It too has a lunch box locker and I know there arent a lot of aftermarket support for this. I have considered switching to a D44 from a TJ (is that even possible) or just keep costs down and buy the truss and 4340 chromo's. Definitely add disc brakes, gear it and selectable locker.
quarter panel protection
prerunner flared fenders - I know they dont hold up well with rocks
minimize the dents, sand primer and paint
beefy rear bumper to match the front.

Pics to follow tomorrow on the XJ and my other passion.

This is awesome. I love what you want to do with the exception of the RC Long arm kit. I think you can get a better running 3-Link from Iron Rock Offroad or HKfab or someone like that that'll be a comparable price. I wish we had places to explore here in Texas like they do in Arizona. There's no such thing as public land here.

I am not even sure I want to do the long arm kit. I have heard bad things about RC but recently there was a youtube video that had to do with RC. . The long arm kit is not even something I really need. I have survived on what I have and done some great many climbs. Check out Payette Draw in Payson, AZ. The end of the trail I cannot believe this Bronco couldnt make up this waterfall. I did it in my 3" lift Cherokee with 33's.
I knew I was leaving something out on my list of stuff I wanted to do. I have a steering upgrade that will be installed as well.

Moog tie rods for a ZJ should be one of the first things you do! It’s a great mod and it’s cheap.

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Here's a pic of my XJ. Not bad for $2500 and 157k miles.

I also have this to play with in the desert for fast driving over whoops and bumpy terrain. Its great to take to the dunes as well.

So I sent out to have my exh manifold to be ceramic coated, should be nice and shiny when I get it in 3 weeks. Jet Hot ceramic coatings reduce heat under the hood by up to 56% and have a lifetime warranty.
Living here in AZ that'll help keep that hot motor cool somewhat.
I am also planning on installing an oil cooler - https://expeditionportal.com/forum/t...nstall.127471/. I have run my air intake out of the cowl as well.

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I have been to the JY twice and found an XJ 1 year older, so 95 and started taking it apart. Its white but I only took the vented windows, door panels and arm rests, trim molding, window crank, side marker lights, switches and front grill. I also found one RE 3.5" leaf online for $80 and will buy another tomorrow. I bought unibody stiffeners from Next Venture Motorsports and got my exhaust manifold coated from Jet Hot. Pictures for that will be Tuesday I hope. Here the rest of the stuff.

It showed up from the friendly gingerbread man. Now I just need to get my horseshoe off and cleaned up.
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Exhaust manifold installed
 

So I decided to spend some time installing the thermal coated manifold. I removed the intake and old exhaust manifolds. Cleaned up the intake, put on the new gasket and got to work tightening bolts.
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3 row radiator
 

Next I decided to install my radiator. I pulled the old one managed to get the quick disconnect line off but the top line broke. Im having a difficult time finding replacements. I checked auto parts store, a mechanic friend and rock auto. I decided to try and get some a/n fittings and make it work that way. More pics to come.

It turns out that the white grill doesn't work with my 96, it must've been from an earlier Cherokee.

a/n connector or stock connector
 

So I got the radiator installed and realized that the quick disconnect isnt snapping into place for the transmission line. It slips onto the supplied connector but slips back off without much effort. After looking at the two side by side, the original one has more of a ridge on it than the new one. Does anyone know of a fix for this or where I can get a different connector? I thought of taking apart the old radiator seeing if the connector can be taken out or going to a hose store and looking for a/n connectors to do something custom.

So talking about the quick connect on the lower tranny cooler line to the bottom of the radiator where the elbow is?
I think they can be removed. Now if you can swap them that is a different story.
Sure you have it all the way on?
You lube up the elbow on the radiator a bit, Vaseline or thinking tranny fluid would work, to not roll the O-Ring in the line in the quick connect.
My first Napa one, rebranded Dorman, ended up not going on my Napa, rebranded Spectra, radiator properly either.
Defected it and the second one has been on for about 7 years now.
Maybe the clips, the little "fan blades", in the quick connect are not bent out as far as they should be.
Would account for it not catching the ridge on the elbow connection at the radiator.

I spent some time recently grinding off the under coat to install my stiffeners.
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Then I started welding on the driver's side. It's time consuming.
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The passenger side is ready for install. These are only the middle stiffeners.
In videos I've seen on the install, disconnecting the brake line and disassembling the shocks and removing the coils are required.

I got the frame stiffeners installed, well welded on. I finished welding them on. I did not do the rosettes on the underside but there's welds all over this that should keep them on. I bought the herculiner for another project but there's enough to use on the stiffener's. While the XJ was at the shop, I had the front end aligned and a weld added to a rip in the frame near the trackbar mount.

Next we installed 4.5" rubicon coils and leafs out back. It's stance it way better than before. New adjustable LCA's were put in, I had adjustable uppers that were already on there and Artec LCA boxes that were welded on. They were put on from an accident I had a few years earlier. New shocks were added as well.

The A/C was looked at and all it needed was freon. I know I needed to install a blower motor and did just that along with a blower motor resistor and MAP sensor. I believe I need an IACV though because it's shifting while in drive with an automatic. I need to clean out the throttle body this weekend and possibly install the IACV if it gets here in time.

The other things I need to get are a new steering wheel. Mine is shot and I can almost see the metal wheel thru the rubber. Quadtratec has them along with a clock spring (mine started coming apart with shavings of copper on my floor board) and a new ignition box. I will order those soon. I also need a new gas tank as mine has dents on both sides. I have been spraying penetrant on the bolts so when I do get that new tank it won't be that hard to disassemble.

I need to order vacuum lines and elbows for everything that requires a vacuum. Does anyone know where you can source these elbows or do you need to order a new line and they come with the elbows?