98 Green Cherokee XJ
 

So have had the Cherokee for about 3 months now. Picked it off for a pretty good deal on CL. Was an AZ/CA Jeep so that meant no rust! Jeep had 250 000 miles on it and was sounding a bit rough. This is my 2nd Jeep, I had a 2005 Jeep Wrangler TJ which I built up previously.

My goal is to build up a Cherokee that can be a comfortable DD, yet still capable of doing trails. I will be using the Jeep to drive to school everyday, and exploring some trails over weekends.

Jeep wasn't in the best condition when I got it. First thing that had to be done was a rear axle rebuild. Now that I look at it I should've swapped out the D35 for a Chrysler axle. But anyways that'll come with 1 ton steering in the future hopefully. Swapped out the wheel bearings and pinion bearing on the D35 and the ride quality was already much better (old right rear bearing was seized up)

Onto some mechanical stuff. Did the basic fluid change of everything, new coil, distributor cap, plugs, plug leads etc. Properly cleaned some of the engine bay as some of it hasn't been cleaned since it came out the factory most likely.

Did some basic changes, like new stereo head unit, mounted a FireStik CB antenna, blacked out the front grille, mounted some LEDS, added a switch plate over the factory ash tray, fabbed up a plate to close off rear cubby hole and some other stuff I can't think of right now.

Fast forward 1.5 months. Ordered a 3 inch RC country lift with full rear leaf pack. Ordered some spacers too for the front. All in all Jeep will sit around 3.75 inches all around. Just bought some 305/70R16 BFG all terrains on MT alloys to mount on.

Near future plans:

Front axle rebuild
Engine rebuild
Front and rear bumpers

Attached are some pictures of cleaning and what not!


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So things are starting to come together. My RC lift arrived and I got all my tires. Have started some pre lift work. Removed my front bumper and resprayed it black. I ordered pre 96 bumper end caps to put on. I'm not planning on keeping the bumpers stock too long but want it to look neat for the meanwhile.

My Solid Dana 30 front cover also arrived and I sprayed the letters red so long. Quite happy with the outcome
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Will hopefully have everything on by the weekend.

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Good start!

Thanks! Its tough on a student budget but definitely possible! Very happy with the Jeep so far

So the pre 96 bumper end caps arrived this afternoon. Just mounted them and pretty happy with the look. Pretty easy and cheap install.

Also started spraying all the necessary bolts this afternoon with PB blaster in preparation for the lift kit I'm putting this weekend


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Started with the back end of the lift last night. My biggest concern was the front bolt of the leaf springs as these are known for not wanting to come loose. I used a spanner and a small bottle Jack and a can of PB blaster to get it loose. I managed to get the drivers side loose. So the drivers side rear is ready to come out. Will hopefully finish the lift tonight/over the weekend.

Below are some pics of the jeep sitting currently


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So I managed to finish the rear lift last night. Was a full brand new leaf pack from RC with a 1 inch shackle extender. Everything went in smoothly and no big issues!

I also removed the rear sway bar for now.

Very happy with how the rear is sitting. My tires a 305/70/R16 On 16x8 Mickey Thomson Alloys.

I should have the front end finished tonight

Attached are some pics
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Managed to get the drivers side coil spring, shock and lower control arm. The passengers side wheels one lug nut stripped and I cant get it off. Have tried everything I have. Went to Sears to get a craftsman bolt extractor set but they were closed. My last option is to weld a bolt onto the existing stripped nut and then screw it off. I can't think of any other possible way to get it off. The casing has already shredded off so it's just the actual nut left.

Attached is a picture of the stripped nut.

Any suggestions to get it off?


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I'd weld onto it. The heat of welding will help. If not something like this:

Thanks for the suggestion. I'll head over to Sears and check out the craftsman set which works the same. I'm hoping I can get it off and install the rest of the lift. If not I'll have to go rent a welder.

Looking forward to seeing this finished. RC isn't known for being the best but many can't argue with the price. The only good about that rear sway bar is using the brackets as bar pin eliminators. The instructions of the lift should tell you to remove it too

Thank you for the comment, appreciated! Yeah I had mixed feelings, but knowing that I won't be keeping it too long (1 - 1.5 years) I thought it would be best bang for the buck. So far I'm pretty happy with the quality, but will give it some proper testing once it's done.

Quick update:

Went to Sears and got a Craftsman bolt extractor set (reverse thread thing that tightens opposite to direction of turn). Unfortunately did not turn, just shredded the metal. This is very strange as it should've come loose by now. I also tried to drill it out, but I stopped once drill bit hit the wheel hub assembly bolt. My only option now is to torch it and break it off that way.

On a positive note, I ordered a FlowTech Raptor muffler for $28. I thought it was a decent price. It's a competitor with the Super 44 muffler.

Attached are some pics of my new stereo install and the switch plate install, which runs the front LED's and aux fan bypass


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Looking good. I feel your pain because I had to cut or torch a few bolts on my front end and I'm expecting more when I replaced my rear shocks. It is a challenge, but I enjoy learning how to work on my XJ.

Thanks man! Yeah struggling with bolts ain't any fun. But it makes you learn your XJ like you said! Goodluck with your build

UPDATE:

Had to unfortunately give up on struggling with the one wheel lug. I drove to a shop opposite my house who cut out the bolt with a torch for me. Got it back and finished the rest of the lift. So now the jeep is DONE! One happy me. Attached are some pics of how its sitting right now. The rear is sitting just a little bit higher than the front, so I think I might drop the rear bracket to the bottom hole which will hopefully even it out.

Here the lift components:

Rough Country 3 inch series 2 lift with full rear leaf packs
0.75 inch coil spacer upfront
Rough Country steering stabilizer
Adjustable rear lift shackle
Front sway bar disconnects
Front Trac bar drop (temporary, planning on putting an adjustable trac bar)

305/70/R16 BFG All Terrains
16 inch Mickey Thomson alloys


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:thumbsup: Looks good

Thanks man!

UPDATE:

Jeep running nicely after lift. Took it just over 50mph and no vibes. This is without a transfer case drop or SYE. I'll still need to take it on highway to see as I am certain there will be a vibe somewhere.

I've had some minor rubbing upfront on the lower edge of the front flares on full lock. So to minimize this for now I trimmed to stock fender flares corner off, it's definitely much better than what it was.

These are my next few upgrades happening in the near future:

FlowTech Raptor muffler
Rubicon Express adjustable front Trac bar
Front axle rebuild.
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Attached is a pic of the jeep as it sits now, with a Firestick CB antenna

looks great! nice clean no rust free jeep to work with. will definitely be watching this build. continue with the great work brother!

Thanks man! One step at a time. Thanks for the interest!

UPDATE:

Haven't done much on the jeep today. The man in brown delivered my new FlowTech muffler. I'll install it tonight once the exhaust has cooled down hopefully. I also have the jeep a well deserved wax today.

I'm very happy with the quality of the FlowTech, I haven't tested it performance wise but the quality looks promising and for the price I paid I don't think it's bad. Will upload a video once everything is installed.

I thought since I haven't posted a pic of the engine bay I would post one!

Attached are some pics

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Looking good man.

Thank you Sir! Appreciated

Quick update:

Started the muffler replacement last night. The old muffler was tough to get off. So I stopped late last night and continued this morning. Decided it was best to sawzill it off. Chopped it off and the rest went in pretty smoothly. Very happy with my "budget" muffler install. I will try and post a video of how it sounds. For me it's perfect, it's got a nice low rev growl and there's no drone when accelerating. It gives a nice aggresieve sound to the Jeep!

Attached are some pics


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Was a pretty cool sunset last night so I thought I would take one or two glamour shots!


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I installed LED's in my instrument gauge cluster. Very easy and cheap mod and very happy with the result. Gives the Jeep a nice modern look. Attached is a pic


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Quick Update:

I ordered a pair of Pioneer 6.5 inch front speakers which arrived today. Quickly installed them this afternoon and made a pretty good difference. I was expecting to atleast drill new holes, but to my surprise the holes matched right up to the stock ones!

Pioneer TS-G1645R 6.5" - Paid $29.99 off eBay

Installed my LED interior light bulbs today. Makes a huge difference and happy with the result.

On another note, did a thorough engine inspection today and noticed something strange. There's some strange anti freeze leaking down the front by the water pump, but it's almost a little sludgey (almost as if it has oil in it)? Jeep hasn't been overheating or losing any considerable amount of coolant. I'm hoping it's just the water pump that's going bad (sounds right for 250 000 miles). Apparently when the pump goes bad the bearing starts leaking a bit of anti freeze. I'm going to order a new pump and gasket, hoping its that.

Any thoughts?

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Look like your thermostat housing are also leaking

Looks more like your thermostat housing is leaking. Although, changing the water pump is still a good idea. It's a pretty easy job and the thermostat housing has to come off anyway. Just replace the pump, both gaskets, and throw a new thermostat in while you're at it.

Thanks for the replies XJWonders and JeremyXJ!

I'll get onto replacing the water pump, thermostat and gaskets! I'm tempted to replace the upper and lower hoses and radiator too while at it

That wouldn't hurt. I replaced my entire cooling system when I got my Jeep.

Yeah sounds good. It's fairly inexpensive and I thought while I'm going to be draining the fluid I might as well start off fresh

Some poser pics from a sunny Arizona!
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Cooling System Overhaul
 

So it seems that the summer here in Phoenix is starting to catch up with the Jeep. Its been 115*F + the last few days and even on short trips the needle has been creeping over halfway. My thermostat housing is leaking, but I thought I will rather replace everything, taking into consideration mostly everything has over 250 000 miles on it.

When I flushed my radiator a couple of weeks ago it seemed fairly clean, but my coolant overflow tank was full of thick sludge and deposits, so that was sort of a giveaway.

So here goes my cart that will be ordered Friday:

Spectra Premium CU1193 radiator ($75)
Gates upper hose ($14.90)
Gates lower hose ($11.99)
GMB replacement water pump ($27.58)
Dorman aluminum housing ($10.99)
Stant 195 degree thermostat ($7.13)
FelPro water pump gasket ($3.62)
FelPro thermostat gasket ($2.00)

Total $153.99

My only two "grey zones" on the above is should I rather get a 180*F thermostat (it is mostly hot weather here all year around) and the other thing is is it a smart idea to use an aluminum thermostat housing, instead of the old school cast iron one?

Any suggestions, or past good or bad experiences with the above mentioned are wecome!

Thanks

Decided to see how much room I have when flexed up (this isn't really "flexing", just getting idea of how much room there is). Stock fenders definitely limiting it quite a bit. So a pair of pocket style flares will be put on soon hopefully. Attached are some pics


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If you haven't already check out Napier flares, they look alot like the BW but cheaper,stronger, and better looking IMO, also get a 195° oem stat, the engine runs best that way a 180° won't help with cooling

Yeah I have heard of them and just checked them out - very clean indeed! Thanks for the info, will hopefully be doing all that this weekend

So been a bit quiet on the Jeep front for abit, but things will start to pick up soon. I'm looking at possibly buying a engine from a scrapyard and build it into a Stroker, build it up over time and then once finished pop it in. My engine has over 250 000 miles on it so instead of spending money on an old engine rather build up something else. But we will see!

Here's a list of things that'll be done over the next few weeks

Radiator
Upper and lower hose
Thermostat housing
Thermostat (195*)
Water pump
Water pump inlet tube
Water pump gasket
Thermostat housing gasket
Radiator cap
Radiator isolator

Front rotors
Front disc brakes
Rear brake shoes
Rear drums

Oil pan gasket
Drain transmission fluid
Put in new transmission oil filter

Replace steering box brace with IRO
Put in IRO steering box reinforcement
Put in IRO steering box cross brace

Install IRO double shear track bar

Install rear shock bar pin eliminators

Change front diff oil
Put on Solid diff cover
Front diff gasket

I'm planning a camping and wheeling trip for the end of July so hopefully that'll happen!

Attached are some pics of the Jeep on back roads in and around AZ


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