91 2dr in the works
I did make a new list of action items that will have to be done soon however. The list is as follows:
Rear main seal
trace down coolant leak
Weld trackbar bracket to frame (keeps coming loose even with lock tight on bolts)
rebuild RE flex joint on trackbar
new steering tre's
axle ujoints
ball joints
Luckily I already have a set of Moog ball joints sitting in the shop as well as ujoints. I can get the bracket welded up without issues and rebuild the flex joint at that same time. The rear main is my area of concern. I know it isn't a hard job but is very messy and really not looking forward to it. I'm hoping I can nurse that leak until it warms up so it isn't as miserable to change it.
Rear main seal
trace down coolant leak
Weld trackbar bracket to frame (keeps coming loose even with lock tight on bolts)
rebuild RE flex joint on trackbar
new steering tre's
axle ujoints
ball joints
Luckily I already have a set of Moog ball joints sitting in the shop as well as ujoints. I can get the bracket welded up without issues and rebuild the flex joint at that same time. The rear main is my area of concern. I know it isn't a hard job but is very messy and really not looking forward to it. I'm hoping I can nurse that leak until it warms up so it isn't as miserable to change it.
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
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From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
Haha the plan of tons is no longer. Full widths are still on the want list but I think I'm gonna stick with 1/2 ton axles. 44/9 combo will most likely be the axles of choice with use of the ford radius arms to make it easier. These can be found all over the place and are fairly cheap. With enough searching, I could probably find a pair that are already semi-built
CF Veteran
Joined: Apr 2008
Posts: 2,340
Likes: 8
From: Burlington, NC
Year: 1994...mostly...
Model: Cherokee (XJ)
Engine: 4.0L I6 HO, Lot's of Bolt Ons
Haha the plan of tons is no longer. Full widths are still on the want list but I think I'm gonna stick with 1/2 ton axles. 44/9 combo will most likely be the axles of choice with use of the ford radius arms to make it easier. These can be found all over the place and are fairly cheap. With enough searching, I could probably find a pair that are already semi-built
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
I made a few deals here and there and currently have the following items waiting for installation...
FF 60 rear
-disk brakes
-4.88 gears
-Ruff Stuff perches so I can stretch the rear 2 inches
HP44 from 79 F150
-Converting to 8 lug
-Installing 4.88s
-Lunchbox locker
-Warn hubs
38/15.5/16.5 Super Swamper TSL Radials
Aluminum 16.5x12 wheels 8 on 6.5 pattern
Already have the general plans so I'm sourcing the rest of the items now. Plan is to build it all outside of rig so that I can still wheel and then do it all in one single swap. I want it all done by the end of July but we will see how the parts sourcing goes.
Last edited by adamk; Apr 13, 2015 at 08:48 PM.
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
I have found a Chevy 8 lug 44 for cheap with warn hubs so I will be picking that up to take everything from the knuckles out and the stub shafts to put on the f150 housing. When I bought the f150 housing, I also got the radius arms. I will be getting measurements for those Wednesday and I'm having the guy who sold me them to weld them up with joints at the end as well as plate the sides.
The steering will be a heim joint, over the knuckle set up. I will be using my rubicon express track bar for now but I'm debating stretching the front an inch or two so I'll let everyone know what I decide.
I will be upgrading the brakes during all this as well. I will be using the late model XJ double diaphram booster with a Dodge 3/4 ton master cylinder. I have not decided what prop. valve I am going to use just yet..
The coil and leaf springs I currently have will be reused for now but depending on how everything goes during final install, I may have to purchase shorter springs to get the ride height I want.
Shocks are another item I have not decided on yet. I've always like the Doestch 8000's so I may go with them but I've got time to decide.
The steering will be a heim joint, over the knuckle set up. I will be using my rubicon express track bar for now but I'm debating stretching the front an inch or two so I'll let everyone know what I decide.
I will be upgrading the brakes during all this as well. I will be using the late model XJ double diaphram booster with a Dodge 3/4 ton master cylinder. I have not decided what prop. valve I am going to use just yet..
The coil and leaf springs I currently have will be reused for now but depending on how everything goes during final install, I may have to purchase shorter springs to get the ride height I want.
Shocks are another item I have not decided on yet. I've always like the Doestch 8000's so I may go with them but I've got time to decide.
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
Well I made the run down to SC to pick up the 8 lug 44. I will be dropping that off at a buddies house for storage this evening when I get measurements for the radius arms.
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CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
Picked up some stock Ford radius arms yesterday so I can cut them up and use just the clamping portion and then build the rest of the arm from there. I also got the Chevy 44 torn down. Found that the driver side knuckle was cracked and the driver side studs on the knuckle were trashed. I ordered another set used from eBay and they should be here next week. I also picked up new calipers for the front and lower coil buckets.
Thread Starter
CF Veteran

Joined: Aug 2010
Posts: 1,220
Likes: 0
From: Greensboro
Year: 1992
Model: Cherokee
Engine: 4.0L
The past two weekends I've been working on the new axles. The 44 front was completely stripped down, cleaned, and painted. I also dropped it off at ECGS for 4.88 gears and a locker. Also on the order sheet from ECGS is ujoints and long side chromo. I've already got a short side chromo. While it has been with them, I got the hubs cleaned and painted and sand blasted the knuckles. I just have to remove the old ball joints and install the new ones I have waiting to go in.
The 60 was this past weekends project. I got it torn apart, cleaned and reassembled. The hubs were completely rebuilt and painted. I also had the rotors turned. I have calipers for it but because this axle was converted to disks by the previous owner, there is no prevision for an ebrake. I'm going to solve this by using Eldorado calipers. They aren't the best by any means but as long as I can bleed them fully and set the linkage for the ebrake just right, it should work well enough.
Once I get the front axle back from ECGS, I'll assemble it and then the real fun begins....Fabrication!!
The 60 was this past weekends project. I got it torn apart, cleaned and reassembled. The hubs were completely rebuilt and painted. I also had the rotors turned. I have calipers for it but because this axle was converted to disks by the previous owner, there is no prevision for an ebrake. I'm going to solve this by using Eldorado calipers. They aren't the best by any means but as long as I can bleed them fully and set the linkage for the ebrake just right, it should work well enough.
Once I get the front axle back from ECGS, I'll assemble it and then the real fun begins....Fabrication!!



