razor02097

Today was the big front end overhaul day. Upper and lower ball joints, new knuckles, UNIT bearings and the ZJ tie rod upgrade all went in.

knuckles where painted with bed liner


New UNIT bearings 2 = $160


Ball joint press. Loan a tool program. You pay $100 to borrow it then get the $100 back when you return it. To those who think these ball joints can be gotten out with cheap tools... I pray you don't get hurt trying... look at how much steel is in the tool!


Time to get started... Removed cotter pin, retaining ring and spring washer. The axle nut is 36mm. Removed UNIT bearing bolts. 13mm 12 point.


Removed the old unit bearing using the socket extension method and BFH persuasion.


Pressing out the top ball joint first


Needed a little coaxing...


Lower ball joint next...


Pressed in new ball joints


Installed new knuckle and reinstalled axle shaft


Installed new UNIT bearing assembly and moved to the next side...


Same routine except... When I got the knuckle off the upper ball joint gave out. I guess I found the mysterious clunk when I turn into a parking lot...





Pressed out the old and in the new... Reassembled and moved to the tie rod.


I matched the length as best visually as I could. I ended up installing it then using a board and a helper on one tire then 2 tape measures and a board on the other tire. Got as close to 0* toe in as possible then tightened it all down.

Afterward it was off to an alignment shop for a proper alignment.


Unfortunately the dust shields where a casualty of rot... they where unrepairable and unusable. I don't think I will make an effort to find replacements unless it is necessary.

Now that the maintenance part is done I can start doing fun things again

razor02097

Starting rust repair and floor prep. First to come out is the cargo area carpet. Looks like a few spots need to be repaired before proceeding. I removed the tar crud before putting a coat of paint to prevent rust until I get to it.









Did find this under the carpet.... build note maybe?

1ABrian

Are you gonna reuse the carpet later or juat make the cargo area a giant tool box? Whats your plans after the rust repair

razor02097

The carpet is too nasty to reuse. I am probably going to use bed liner on the floor and put a large rubber mat over that. Then use rubber undercoating underneath. Should be quiet, water proof and much more usable.

razor02097

Trying to keep this build going... had a pair of Kenwood 6"speakers I had from a previous project. I decided to try installing them in the back of the Cherokee.

Believe it or not they bolt up without modifications.

First remove cover


Then the 2 t-20 torx screws


Remove factory plug by lifting tab and pulling off plug


Comparing old and new. Notice the mounting ears on the old speaker stick out.... this is why the larger speaker bolts up.


Now I adapted the factory harness by tinning the wires and plugging them in.


Now I bolted up the new speaker


Last I reinstalled the cover and tested.


All is well. Simple cheap upgrade.

razor02097

Onward....

The rest of the nasty carpet is gone. Good news is the drivers floor pan is in great shape!


I cleaned it up and put a coat of paint on until I get all the repairs done.


The bad news is the passenger floor is doomed.....


It looked bad... I cleaned it up and sure enough the rot is clean though.


After cleaning I put a coat of rustolium on just to provide corrosion resistance until the weekend.

I figured the road noise would be terrible so I took an old license plate to cover the gaping hole and placed the floor mat back on.


At least it will be okay for tomorrow. One last thing. I found a sheet that says XJ mandatory pos-buy record... thought that was interesting.

razor02097

Sunday 5/29/2011

Time to do something about the passenger floor...

Got the seat bracket out after a lot of fuss...


With the angle grinder i set to work removing the cancer.


Drilling out the spot welds was pretty easy all in all. I used a small crow bar and hammer to knock the sheet metal off.




Now I made a template and cut out a replacement panel out of 16 gauge steel. Covered the dash and welded it in.


Still have to seal it and install the seat bracket.

Monday 5/30/2011

Glorious memorial day. Thank a soldier and a veteran if you get a chance.

Today comes more cancer removal and repair... the rear quarter...

Yikes.... the angle grinder and sawsall come out to play again... I didn't get pics of the whole process because frankly I forgot in the 93* heat. The rust was cut out and from this pic you can get an idea of how much it was...


I ended up hand forming and welding in 3 pieces total. #1 and 2 was the back side and three was the outside body panel.


After forming the last piece I welded it in. I used metal fill and Seam sealant around all the welds to help get in all the tiny nooks inside and out.



After sanding it down on went the plastic filler.


After it dried I sanded it, primed and painted the closest rattle can color I could find.


On this pic you can see the color is brighter than the original. The line is from the tape and above that is the filler dust I haven't cleaned yet.


Okay 2 big repairs down. One smaller one to go....

Oh I made use of the drying time also. I scored a 7' whip antenna locally for $20. So I mounted it up using some brackets that originally held an ultrasound machine to it's crate.... they are 1/4 plate. Bolted 2 together and that to the bumper.


Mounted the antenna.


Antenna up


The hatch just barely contacts it when opening.

razor02097

I guess I better make sure my tetanus shot is up to date.....

razor02097

Today was another hot day... Most things completed was cleaning all the tools accumulated from driving back and forth to the shop...

I did manage to install the seat bracket.


Completed the last patch... Since it was by the fuel tank and I didn't want to barbecue the Jeep I made sure to stuff a welding mat between it and the floor while I welded in the patch. Afterward I started to smooth it out cosmetically with plastic filler. In fact I will try to smooth as much as possible since I'm not covering it with carpet. Any repair more than 1/8" will get epoxy filler first. It doesn't tend to expand and crack like plastic fillers do.



Last I removed the rear seat back and started removing the seat belts with a T-50 torx bit... stupid bolts where really corroded so I only got 2 out so far...



I have been continually soaking them in penetrating oil. Wish I could use an impact and get it over with but I know that would end in disaster...

It seems like progress is so slow... it's frustrating as heck...

razor02097

Got the seat belts out and almost finished with the tar mat removal. This is the worst time when all the little things need to be done in order to get the floor prepped right before slathering on the bed liner.

Not really anything spectacular to see so I didn't bother to take pics.

razor02097

Well started the big part today. Took the rest of the interior out and prepped the floor for the first coat of bed liner.



Tied all the wires off the floor. If I'm going to do it I will do it thoroughly.





This wire harness goes to the fuel pump. I just went underneath and disconnected it then pulled it through.



Removed the ebrake and air bag module. Pretty much everything but the shifters.





Good thing I recently overhauled the rear brakes....





Got the first coat applied.



Waiting for it to dry.... sine I did it so late I will apply the second coat tomorrow morning.

razor02097

Second coat is on

razor02097

Started to assemble interior.

A trick to get the rubber plugs in.


Use a socket that fits inside


Push gently it should pop right in


Done


Installed back rest plates. There is one last coat of bed liner going on the back these will get coated when that goes on.


Got the ebrake and air bag sensor installed.


Seat belts



Rear seat back


And front seats


And the rest of the back seat belts


Seat cushion


Finally the spare

razor02097

Routed CB cable





Up to the CB.



Now I need to find an swr meter.

razor02097

I'm going to pick up a 3' antenna after work today. I'm getting sick of tying down my whip antenna every day to enter the garage at work. I guess I will have to build a new mount and mount it up higher.