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Nice job Jake. I'm getting close to starting a similar effort on a '92.
You ever sell your vent windows? I liked having them on an old Ranger and might consider changing out the XJ.
Sorry, Giego. I have been so busy and haven't updated my tread in a while. I sold the vent windows. If your still looking, I recomend going on car-part.com and find a local JY that has a set.
You can get them for like $50 if you pull them yourself.
Update:
I have been daily driving the jeep for a few months. I have been working out the bugs, and the only real issue I've had is the vibration that I fixed with an ignition overhaul.
Since my last post, I've replaced a bunch of front suspension components, the transmission mount, the coolant sensor for the ecu, and done an oil change.
The front springs, bump stops, and isolators looked pretty tired. It had new shocks, so I didn't touch those.
The springs came with the jeep. I have HD rear springs, so I wanted HD fronts. I wasn't sure if these were, but they were free so I tried them. Turns out they were super light duty, and sagged worse than the old ones. Eventually I am going to buy some Moog CC782 coils.
The spring isolators are Crown, and the bump stops are off eBay.
For some reason I didn't take a picture after it was all done, sorry.
The sway bar bushing were shot and squeaking. I painted the sway bar, and got new links and bushings.
I got a new Crown tranny mount. I seems okay, and fit well.
No worries, just thought I'd try and see about gathering some parts. About to start cutting out the original floor panels on my '92, so have plenty of time before I get to that.
New injectors!
My old ones were fake eBay bosch injectors. They all leaked.
I picked up a set of rebuilt flow-matched 746's from CS Performance for $130.
My fuel pressure would drop 20psi. in a few minutes. I isolated the injectors by pinching off the fuel lines for this test.
I removed the battery clamps and put them together. Then turned on the ignition and lights, to drain the system and reset the computer.
New injectors:
You can see here the comparison.
At least, I think the old ones are fake. I guess maybe bosch made some with that metal part, and some all plastic.
Added some more color to the engine bay.
I also cleaned the O2 sensor.
And the IAT sensor. When I went to remove it, it was loose.
My coolant gauge has never read over 110 degrees all winter. I replaced the sender, which didn't help. I tested the gauge, and it appeared to work. I never considered that the jeep might be running cool, even though my heat was weak as well. It was warmer today and the gauge got up to 160, so I checked the block temp with an IR thermometer and it was 160. I thought maybe a stuck thermostat, so I bought one.
Popped the cover off and...
If I remember correctly, there is supposed to be something in there.
My thermostat was missing.
Cleaned up the mating surfaces:
Gasket dressed with RTV:
I drilled a weep hole in the new thermostat.
Back together.
And running at just under 210. Finally. Hoping my MPG's will improve.
FINALLY! THE RUST WORK IS DONE.
I am very excited to be so close to finishing this restoration. I am the proud owner of a rust free XJ in the northeast.
A friend helped me finish the rockers last week. Now, all I have is a little dent filling and it will be ready for paint.
I have the Jeep scheduled for paint at Maaco on the 26th. I am going to strip the old paint myself and do the final body filler work. Then bring it to them.
Up until now it has been my daily, but I can't stop working and it needs to go in the garage for a couple weeks for that work before paint.
So...I bought a 1999 Ford Ranger as a new daily. It's the 4.0 V6 with 4x4. Unfortunately it's an auto. Despite it only being 10 years newer, it drives like a Cadillac compared to the jeep.
Paint prep has begun. I have about a week to get the jeep prepped for the body shop. I discovered that the jeep had a cheap respray before. That's why the paint was so dull. There was no clear coat.
The hood was pretty bad, so I took it down to bare metal.
Here you can see the respray layer on to of OEM base. It appears they went through OEM clear...Maybe? Not totally sure what I am looking at.
Fender was new with just primer, so I sanded with 180 grit.
So I really dont no how much I need to sand with the good condition OEM paint on these doors. I started by sanding right down to primer on the lower portion, but decided that might not be necessary and just sanded the clear on the upper portion.
Can Any Body Work pros chime in here? I am looking for a great looking paint job that will last a few years. It doesn't need to be perfect for the experts. I just want it to look great to the average person.
Does anyone know if this is enough on the areas that are in perfect shape?
This dent will need filler so I went down to metal. On these areas I am trying to fade it with all layers visible for a smooth transition from metal to paint.
If you guys have any suggestions or see issues, please chime in. I'm sure the shop will have to make some adjustments when they get the car, but I'm just trying to do as much work as I can with no experience.
Last edited by JaketheSnake1; May 19, 2025 at 06:53 AM.
I finished all the prep work a few weeks ago. I haven't had time to update this thread. The jeep is in getting painted now. There was quite a lot of body work to be done. When I got it to Maaco they told me $3500. I was surprised, but really had no choice so I gave it to them.
It should be done next week.
The Jeep is painted! There was a small spot of the body work that needed to be adjusted on the passenger quarter, but overall an incredible job. The color and clarity of the paint is excellent. The finish is very nice with no orange peel. I will upload more and better quality pictures next week, so you can actually see the finish. I went with the original color.
Heck yeah man, that is awesome! I can't wait to get mine done one day when the budget allows. I'm going to stick with original color also!
Thanks for the encouragement. I'll get some better pictures soon see you can really see the quality. I would definitely recommend Maaco if you have a good one. They vary by location for sure.
So...it's been a while. I am working full time and trying to finish school. That doesn't leave much time for the XJ. I have been working on it but I haven't had time to post.
It is basically done. The last few months have been just slowly putting the interior back together, reinstalling trim, and little odd things to make it right. Since my last post, the jeep has gotten a new front bumper, all new front bezels and lights, new OEM style fender flares, bumper ends, bumper guards, restored emblems, and many other things i won't list. I also restored the old seats that were badly stained. All that is left is to reinstall the driver seat, moog cc782 coils for the front to correct the rake, and maybe repaint the wheels.
I will post final pictures soon. It is very dirty from sitting, but here's a few teasers.