93' 2D Cherokee Build
 

Pretty new to the forum, but im excited about my first XJ Project and figured I would start up my build thread.

I found my XJ in the back of a guys yard, he said it ran he just no longer used/needed it anymore. So it wasnt in perfect condition, but if I could get it at a good price. And I did, :-) I picked up my XJ for a trade on a sound system for the guys son, and was able to drive it 45miles home!

Its a stock 2D 1993' Jeep Cherokee Sport with the 4.0l mated to a 5-Speed trans and ofcourse got to have a 4x4.

It runs strong, while test driving it I was able to smoke tires in first and second so I know it has power. The tires need replace anyway, they are bald, and I wanted to see what kind of power it had so why not have fun with it lol. So it has power, I decided it needs a new slave cylinder which kind of sucks because its an internal slave cylinder, so far Ive dropped the transmission out of it and am currently putting a whole new clutch kit in to avoid the need of dropping the transmission in the near future.

I did notice, that the pilot bearing from the motor did not match up to the pilot bearing that fits in the 93' jeep cherokee motors? I took the old pilot bearing into autozone, and they informed me that the bearing must have come out of a 94' and above motor? So I've got a new pilot bearing for the 94' motor and it fit perfectly. It was a bit odd, but figured that could mean that its had a new motor put in it somewhere along the lines. I have yet to run the block numbers but I will be doing that soon.

Future Mods Include:
Tube Bumpers front and rear
Rock Sliders to replace rusted rocker panels (Dont know if I want Boat sides yet)
Conduit Constructed Roof rack
Budget Build lift kit

Like most here, Im building to suit my budget and as a college student myself its not that big. So hopefully Im going to be fabricating as much as I can and learn some new tricks from you guys on the forum.

Sorry about NO PICTURES, Im at work, and dont have the pictures with me.

Well its taken long enough to get these pictures on here, but things have been hectic.

So this is what a 4y old $300 sound system gets me

Its got mileage, but it runs like a champ.
http://farm2.static.flickr.com/1180/...de91f1a7_b.jpg



Drivers Side (Paint Peeling on Hood)
http://farm2.static.flickr.com/1033/...3baf69a9_b.jpg



Rear Hatch (Mid-Clutch Replacement) The old slave cylinder had seen the end of its time
http://farm2.static.flickr.com/1420/...2ab07e74_b.jpg
After the install of the new clutch kit, it turned out that the internal slave cylinder that I was sold was bad. So I had to drop the transmission AGAIN, to install another slave cylinder.


Rear View Passenger Side (a little damage below the 4x4 sticker, not too bad though)
http://farm2.static.flickr.com/1392/...e273eb8e_b.jpg

Rear view drivers side, windows busted. (my wrenching help alongside)
http://farm2.static.flickr.com/1005/...96c2243d_b.jpg


New clutch kit, brings my grand total up to $176 for my cherokee
http://farm2.static.flickr.com/1165/...a8a69ed7_b.jpg

Come to find out, the clutch kit was the right match for the jeep, but the pilot bearing in the motor was not consistent with that of the motors produced in 93'?

I ended up having to get a pilot bearing from a clutch kit for a 95' cherokee? I dont know if this is a new motor or not, there is no record of a motor swap. :-? Ill have to check the block numbers


The clutch still wasnt working properly, I ran into the hydraulic line dilemma everybody is having. I actually cut the line thinking I could find one cheap and easy. WRONG, I ended up trying to use a 6" secton of transmission hose clamped down to the line to try and suffice, no go. So I go the dealer price of $180, and decided the bone yard was the way to go. I picked on up for $10, and a master cylinder for $16 so a whole new hydraulic clutch setup, and were running strong!!

Also, thought I might add, my car finally crapped out on me. So this cherokee "project" has now become DD for the time being. Until I find the time to fix the car :-( i wanted this to be my new toy


UPDATE: Going to fabricate up some front coil risers, its something new. Everybody else is running coil spacers fitted on top of the coil, I got ties with a suspension shop and got a hold of some seats for the coil springs and am going to use them to raise the lower mount for the front coils, this should level the jeep out for now until i do a bigger lift. Im planning on gaining 2-3" out of this lift

Yesterday I got the new front coil cups completed, and installed. It sits a little high in the front now (about 1.5" higher than the back) but it looks good.

Problem:
From all the years that this thing has sat sagging in the front, I think the steering parts have worn out. Now occasionally going down the road the two front tires begin to shake violently unless i slow down a little bit. Once I slow down, I can increase speed again and no problems. It doesn't matter what speed I am going at its happened at 35mph and its happened at 75mph and everywhere in between.

I've replaced the steering stabilizer, and that helped a little "not as violent" but it still goes into the shaking frenzy every now and then. My wheel bearings squeak, so Im replacing the hubs next. Any ideas on what could have caused this after lifting the front up? It never happened before, and just happened after i lifted the front.

I will post pics up later today on how it sits now, and what the install looks like when completed. unfortunately, it was raining and i had no camera so the only way I can show you what I fabbed up is the finish pic and a 3d render.

Before pictures:
http://farm5.static.flickr.com/4096/...fd815873_b.jpg
Trail Ride in Geneva, FL

http://farm5.static.flickr.com/4097/...60561825_b.jpg
Flex shot before the lift, I will do another same spot with the new lift on to see what kind of difference we got.

http://farm5.static.flickr.com/4137/...cc13f908_b.jpg
Front coil Seat Lift in 3ds Max, similar to a coil spacer, but more durable, this isnt going to wear out

Tan parts are 1/4" steel

http://farm5.static.flickr.com/4120/...cd841de2_b.jpg
Separated view of new part

Its worked so far, the only problem im having is with the vibration. But thats nothing to do with this, thats from worn parts. Tell me what you all think, and I will have pictures of the installation later

And here is a pic of the installed seat, it was a little dark out so i had to pull a light up on it. So excuse the bad pic, but it gives you an idea of what it looks like.

I ordered the new wheel bearings (hub assemblies) timken for $110 a piece, and also noticed that the track bar bolt had stripped out and was loose. I replaced the bolt and tightened it back up, and no more shaking! So the wheel bearings will just help out for an overall improvement in handling and riding.

I know i need new sway bar link bushings and new isolators for the coils, but i think i am going to be replacing the coil with larger coils and another seat like i did on the bottom and bolt it at the top to "sandwich" the coil between the two. does this sound like a bad idea to anybody, or is it best just to go with a nylon spacer to eliminate the worn out isolator?

Tell me what you all think, ive got no input so far

Coil spacer is cool, pretty neat that you modeled it out.

Nice wrench helper! :grin:

Looks pretty darned good for something you traded an old sound system for. Good find.

thanks, the modeling was to get an idea of what would and wouldnt work. what you think about the seat on top as well?

I finally got out to the same place to shoot an after shot of the lift.

heres the before and after, there is a substantial amount of difference in tire clearance.

Ive also got some 32" tires that are currently on chevy rims, as soon as I find another set of jeep rims I will put them on and see what it looks like. unfortunately the 32"s are regular street tires for now. But it will give me a better idea of how much higher I need to go for target 35"s

Soon will be coming up with floor pan replacements, there are many rusted through holes in the floor since the jeep came from PA the salty roads has taken its toll

Also looking for material for rock sliders to replace the current rusted out rocker panels, and also custom tube doors

For now, I am collecting the rest of the parts for my front end, I have both wheel hubs for each side, new ujoints and now looking for axle seals once i get the axle seals, i will try and knock the whole front end out in one shot as a weekend project.

wow i love your black 2 door!

nice build! great work on the coil bucket. Do you have the spring clamped in at all tho?

thanks for the support, lol havent gotten too much feedback yet. guess the build isnt moving fast enough.

to answer your question about the spring, no at this time its not clamped in or anything because the shocks that i have at the moment wont allow the springs to extend all the way anyway so i know that they wont pop out of the buckets. once i get new shocks, i will put some sort of clamp in there to hold them in the buckets

Update:
Im picking up a 2wd Comanche tommorow, found it in somebodies back yard for $50! score

The body is straight with little to no rust, the hood is the only thing with some surface rust. It was parked and never driven so its just sat there, I got a feeling it will start after a little cleaning and Carb Cleaner!

So the comanche will either become my DD and allow me to play with the XJ, or if it doesnt run, then it will be my XJ donor vehicle.

so i know this build isnt moving fast at all. im moving so the jeeps been used everyday and this weekend will be my first time getting it out to play in a while.

so i finally got all the front end upgrades ready to be put in this saturday before we go out that night. just a list of what im hoping to get done.

new ball joints, uppers and lowers
new hubs + bearings
new u-joints
1new sway bar bushing

unfortunately the 32"s that i had on chevy rims were no good, after installing them on the jeep rims, they had bubbles in them :001_unsure: so they had to go. but i scored a set of 31" wranglers for $120 and those will do just fine for the time being. the new property has another cherokee on it at the time, im trying to work out a deal with the seller to possibly leave the cherokee there, that would give me another toy for backup.

near future plans:
new crossmember for tranny+transfer case, custom made long arm kit.

I have to upgrade to long-arm before i go up to 6in lift, also going to fabricate a custom adjustable track-arm possibly track-arm bracket drops as well.

do i need to make any adjustments with my steering linkages? will i have to lengthen anything?

thanks for replies in advance

I was going to suggest track bar for death wobble as mine is doing it too. You found it before I could post. Mine is on 35's with 4in lift....rub like crazy, so 6.5in lift here I come! lol looks good though. (yours)

:gunsmilie:Love the two doors...You got a real good deal and a very cool project..Goodluck and keep posting pics and mods....

Well its been a little while since ive updated this. And I have been workin on the jeep, just been so busy working on it and not taking that many pics.

So far, I have replaced these parts on the front end.
New U-Joints
New Wheel Hubs
New Right brake caliper
New right upper and lower ball joints

I checked the driver-side ball joints and they seem tight, no play at all. The passenger side was loose though. I am still getting this clicking / popping feel when I turn in 4wd tho. Im not so sure of what the cause of this, I thought it was the bad ujoints, apparently not. could it be the gears inside the axle?

My conclusion is that Im probably looking at upgrading to some sort of gear upgrade in the front end.

On another note, I did start working on my roof rack. I am using 1/2in conduit with 11guage expanded metal floor. And three crossmembers supported with 3/16" 2" x 1" Steel Channel. I will be using this to mount ten auxiliary lights and carrying extra gear out.

I will upload pics as soon as I get them from my camera