XJRed96

So this is my first build thread but the build has been going on for a while, this is just to help me keep track and stay motivated in this endeavor that is building an XJ. My first Jeep gave me my namesake but was abruptly taken from me when someone slammed into it and totaled the Jeep.
After driving the girlfriend's mom's Chevy Malibu for few months I ended up buying a 2011 Subaru Legacy to compliment the 2000 Chevy Impala that we already owned. Love the Legacy and have always loved Subarus. Fast forward to 6 months after the Legacy purchase I had the car stolen from in front of my parents house on a Friday night. The car was later recovered 5 days later with nothing but permanent marker graffiti over the interior, 600 miles on the odometer that weren't there before, and a trunk full of woman's clothes (the guy was a mentally ill cross dresser).
Despite all that the day after the Subaru was stolen the girlfriend made a turn she shouldn't have and totaled our Impala. (it was a rough weekend). I bought a very clean 1994 Volvo 940 sedan from a customer at my shop who no longer wanted to invest the money into the car to maintain it and we drove that for 6 months.
I then inherited a 14 ft fiberglass Bass boat (Merc 50HP) and equipped the Subaru with a hitch. The Subaru can tow and launch the boat just fine but I knew if I wanted to take the boat any further than the local launch I was going to need something a little bit more equipped for the task. Enter the Latest Jeep.
I acquired the Jeep from a local landscaper who parked his equipment in the parking lot of the pizza joint I occasionally part-time at. Sold the Volvo for a profit to the GFs parents and bought the Jeep. Which worked out because I had sold the same guy my old oversized tires off my 96 and was able to buy them back for 20 bucks less than what I sold them for.

#BlackJeepsMatter
1998 Jeep Cherokee Sport
4.0L 4WD
Chrysler 8.25 RE
NP242 TC
Rolled over 180K as I drove the Jeep home for the first time.




First car wash during First drive home. Car did a lot of sitting, the original owner appeared to have taken pretty decent care of it Most of the neglect came from the person I bought it from




PO's kid smacked up the Driver front pretty good. but everything is still fully functional




First Weekend and its first trip to Deer Camp. Also worth noting after 12 years of hunting i'm finally relieved to say I got my first Buck. not very big probably only 2 yrs old 3 pt.

XJRed96

• Oil Change Mobile 1 10w 30 / Lucas/ Wix Filter 21515 (When bought 11/15 @180,000(Exact))
• ATF Drain and fill - ATF+4 and Lucas (When bought 11/15)
• Trunk Shocks / Rubber stops/ Secured Trunk Latch (When bought 11/15)
• All Three Wipers (when bought 11/15)
• Steering Wheel Grip (when bought 11/15)
• Rear main Brake Line - 3/16" (12/15)
• Both rear wheel cylinders and adjust rear drums (12/15)
• Rotation crossing tires to the rear (12/15)
• Cut Front rotors serviced calipers ( DS Sticking) (12/15)
• Thermostat, Thermostat housing and Heater core Flush (1/10/16)
• Transfer case Drain and Fill - Full Syn AT (1/10/16)
• Adjust Transfer case linkage (1/10/16)
• Repaired Driver Window Switch (1/16)
• 5 1/4" Front Door Speaker and Wiring [Kenwood DS Only] (1/10/16)
• Hood Latch Release cable{Amazon} (1/19/16)
• Radiator Cap and Overflow hose clamp (1/10/16)
• Both washer pumps{Amazon} (1/19/16)
• Battery [AC Delco Group 34] (1/19/16)
• Radiator [Spectra{Amazon}] (1/22/2016)
• Water Pump [Napa] (1/22/2016)
• Transmission Cooler [Hayden{Amazon}] (1/22/2016)
• Radio [Kenwood] (1/30/2016)
• Front Sway Bar Bushings [Moog{Amazon}](2/6/16)
• Front Sway Bar Links [AC Delco{Amazon}] (2/6/16)
• Removed Rear Sway Bar (2/6/16)
• All remaining Speakers [Kenwood] (2/7/16)
• P0304 - Cylinder 4 Misfire (3/15/2016)
○ Misfire on startup noticed, cleared up after 10s.
○ (3/28/16) Fuel Pressure Drop down test results : 45psi to 20 psi in 2 hours. Suspect a leaky #4 Injector
○ More than normal coolant consumption has been noticed.
• Rear wheel Bearings and Wheel Seals [Yukon Bearings {Amazon}] (3/18/2016)
• Repaired Passenger side Lower Shock Mount (3/18/2016)
• Rear AAL [Explorer ProComp{Amazon}] (3/18/2016)
• Rear King Pin Eliminators - [Rear Sway Bar Brackets] (3/28/2016)
• Rear Shocks [Explorer ProComp ES 9000{Amazon}] (3/28/2016)
• Installed Hitch [Curt Rounded tube Class III {Amazon}] (3/28/2016)
• Mobile 1 Synthetic Oil change 10w-40 and Lucas Oil stabilizer (04/13/2016) 184,800
• Fabricated spare tire holder (4/13/2016)
• Repaired driver seat (4/13/2016)
• Rear Shackles (1" Daystar{Amazon})(Not installed)
• Replaced all 6 Fuel injectors Ebay (5/5/2016)
• Muffler and Tail Pipe (Dynomax){Bryan's/US Tire} (06/2016) ~186000
• Full Tune up[Amazon] (07/09/2016) ~187K
○ Spark plugs [NGK]
○ Distributor cap [Accel]
○ Distributor Rotor [Accel]
○ Spark plug wires [AC Delco]
• AC Install
○ AC Compressor [Delphi] {Amazon}
○ Receiver/Drier [Spectra] {Amazon}
○ Orifice tube/line [Four Seasons] {Amazon}
• Cleaned Throttle and IAC (7/12/2016)
• TPS Sensor (07/2016)
*Edit added everything below this and before main text on 3/19/2017)
• Driver Window Switch - Dorman (08/2016)
• Synthetic Oil Change Mobile 1 10w 30 With Lucas Stop Leak (9/18/2016@ 190,000)
• Front Coil Spring spacers 1.5" {Daystar}[Amazon] (11/15/2016 @ 190,000)
• Front Shocks {Pro-Comp} [Amazon] (11/15/2016 @ 190,000)
• 4 Tires 265/70r15 (or 29.6X10.4R15) {Cooper Discoverer AT3} (11/15/2016 @ 190,000)
• Rear Shackles (1" Daystar{Amazon})(11/15/2016 @ 190,000)
• Rear Shocks and Boots {Pro-Comp} [Amazon](11/15/2016 @ 190,000)
• Rear drive shaft U-Joints and straps [AC Delco]{Amazon} (10/4/2016 @190,700)
• Clockspring [Dorman]{Amazon} (10/4/2016)
• Window Switch - Warranty (10/4/2016 @191,700)
• Used Cylinder head- Machined [Elgin Super] (02/2017 @ 193,100)
○ Head gasket set {Fel-Pro} [Ebay] (02/2017 @ 193,100)
• Freeze Plugs - Brass {Sealed Power} {ebay] (02/2017 @ 193,100)
• Engine mounts {Anchor} [Amazon] (02/2017 @ 193,100)
• Oil Filter Adaptor O-Ring {Fel-Pro} [Ebay] (02/2017 @ 193,100)
• PCV fittings and Grommets {Dorman} [Advanced](02/2017 @ 193,100)
• Full Synthetic Oil Change 10w-30 {Castrol}[Advanced] (02/2017 @ 193,100)
• Lucas Oil Stabilizer {Lucas}[Advanced](02/2017 @ 193,100)
• 136 Amp Alternator Upgrade {Ac Delco(New)}[Amazon] (03/14/2017 @ 193,300)
• New Drive Belt {Mopar}[Amazon](03/14/2017 @ 193,300)
• Blower Motor Resistor and Harness {APDTY}[AMZN](04/29/2017 @ 193,300)
• Rear Axle Pinion Seal {Fel-Pro}[Ebay] (04/29/2017@ 193,300)
• Rear View mirror Auto Dimming{Jeep}[2000 GC] (04/29/2017)
• Front Pads and Rotors {Powerstop}[Amazon] (05/3/2017 @ 193,380)
• Front Brake Slides {AC Delco}[Amazon]( 05/03/2017 @ 193,380)



So I haven't installed the AC components yet. The seller replaced a seized AC compressor with an idler plate. I've got all the parts ordered and delivered and I'm hoping to get the parts in on Sunday (my only day off this week) then I will recharged it on Monday and hopefully find that there are no large gaping leaks in the condenser or evaporator.
Also on the repair list is a new TPS sensor (15 bucks off amazon hopefully it lasts at least a few months because I've been bleeding money into this and didn't want to spend another 80 just yet. I also need a new clock-spring as well.(Driver squib faults and airbag light, also no horn most of the time). Also during the process of diagnosing the TPS and Clock spring I'm finding that I am having a very difficult time communicating with the TCM and SRS module. *Low voltage to scanner* I've checked the ground at the P/S rear of the engine and that's ok. after checking the connection at the TCM I was able to get into both modules to read faults and clear them. But when I went to try and reconnect with them later I was unable too again. So that's also on the To-Do list.

XJRed96

Before the AAL




After the AAL. I have not installed the the shackles yet because i'm going to also replace the rear leafspring bushing at that time as well. I just gotta find the motivation, and I would like to get the front up a little bit first.

More photos to come later.

cvc944

Very nice! Black has always been my favorite color on all vehicles. When I was driving them it was only me and hearses on the road. Later the Gangstas started in. Now cars only come in white, black, and a thousand shades of silver. I don't know if I ever saw a black XJ on the road.

XJRed96

Just quickly updating...
I've installed the $15 TPS that I needed and Hot Damn it worked I couldn't believe it. If I get 6 months out of it I'll be thrilled. If some how it lasts a year I will be truly amazed.I will say its nice having my normal shift points and power restored.

Also finally got all of the AC components installed. After a 45 minute vacuum session and quick leak down check period I'm happy to say I will be as cool as a clam as we enter into 100 degree territory here in the Midwest.

No photos this time but more to come this weekend.(hopefully)

XJRed96

Alright so since July...

Daystar front spring spacers.1 3/4 + original spacer.
Daystar Rear 1 3/4" Shackles (Greasable)
p265/70r15 Cooper Discoverer AT3 tires
New AC Compressor, Receiver drier, and high pressure line.
Clockspring
Driver window switch.

Currently have the head pulled off. cylinder 4 was leaking coolant into the cylinder. also with the head off I will be replacing both the engine mounts and trans mount. Replacing all the freeze plugs with Brass plugs. Oil filter adapter seal. and full head machining with valve grind etc.

Also have the rear diff pinion seal and the forward output shaft seal for the transfer case.
and my power-stop brakes have arrived for the front which will also be going on once i get the head back and start reassembling.

BulletProofTech

Not a bad looking jeep but seem to be in to the checkbook with it, but keep up the work, cant wait to see it when its done!

XJRed96

I'm an auto tech and i'm able to do this work after i get off, this vehicle is my hobby/boat hauler. keeps me out of trouble. although speaking of getting in to deep to the checkbook just found out from the machine shop that the cylinder head is cracked on the deck between 3 and 4 cylinders. sooo.... currently trying to source a good used one.

XJRed96

This is actually not my boat, mine is considerably smaller than this. thats a 16.5 ft Lowe deep V



New shackles (painted with VHT Black Chassis paint)



Original tires on an AAL and Shackles. After driving for about 6 months with the AAL I did find a broken leaf in the DS Pack. new leafs next.



Before Cylinder head dissasembly



Parts on Parts on Parts. Mounts, seals freeze plugs head set.



After cylinder head dissasembly. Note the Number 4 Piston



Cylinder head off ready for machining. although not that it's a big surprise found it it was cracked after they got into it.

XJRed96

You can see that the 4th plug back is leaking, also the rearmost plug was of the rubber variety and was also leaking.



Surprisingly the block heater was not leaking, also you can see the failed engine mount.



New Brass Plugs.





Block Deck prepped, Cylinder walls wiped down, Engine mounts installed.



New Adapter O-Ring. PITA but considerably easier when done with the mounts.



Used cylinder head after a trip to the machine shop.



except for a little whipe down ready for the rockers, manifolds and valve cover.



Cleaned the valve cover and shot it with Engine Enamel Clear Coat. same with the intake manifold. Thought about repainting the valve cover but the sticker was still legible on the front and I didn't want to lose it.



Runs like a dream. Although Now the alternator is bad, which it acted up a couple times before the job started so i'm not surprised. Going to upgrade to the Chrysler 136A.

XJRed96

Also the other thing to note is that during the down time of getting the two heads prepped and waiting for the second head to arrive I had every nut and bolt I removed soaking in WD40 Rust Soak. after nearly a month the majority of the bolts looked like brand new sans the pitting on the more serious rust. Intake/Exhaust Manifold bolts in particular. I also used a new Head bolt set.

XJRed96

Been limping it along with this bad alternator fortunately the jeep is only my toy and not my dedicated Daily Driver, Finally have an opportunity to do it tonight. Got a 136 Amp *Ac-Delco New* for the Grand V8 and a Mopar belt. Will also be upgrading the battery cables from the battery to Alt and to the PDC. Also got my new Resistor which I went really cheap on so we'll see what happens. just hoping the harness isn't burnt up like they almost all are on Chrysler products.Also i may also put the Power Stop brakes on that i've had sitting around for a couple of months now. Those are what i'm most interested on.

Also another update I'll be buying a WJ V8 from a customer for 300 bucks that has a blown motor. but does have a leather interior with power and heated seats that i'm excited to get in the XJ. Will likely also pull the Booster and Master as well.

XJRed96

Haven't updated the Work-Performed list in a while. This is everything i've done since the TPS and Throttle service
• TPS Sensor (07/2016)
• Driver Window Switch - Dorman (08/2016)
• Synthetic Oil Change Mobile 1 10w 30 With Lucas Stop Leak (9/18/2016@ 190,000)
• Front Coil Spring spacers 1.5" {Daystar}[Amazon] (11/15/2016 @ 190,000)
• Front Shocks {Pro-Comp} [Amazon] (11/15/2016 @ 190,000)
• 4 Tires 265/70r15 (or 29.6X10.4R15) {Cooper Discoverer AT3} (11/15/2016 @ 190,000)
• Rear Shackles (1" Daystar{Amazon})(11/15/2016 @ 190,000)
• Rear Shocks and Boots {Pro-Comp} [Amazon](11/15/2016 @ 190,000)
• Rear drive shaft U-Joints and straps [AC Delco]{Amazon} (10/4/2016 @190,700)
• Clockspring [Dorman]{Amazon} (10/4/2016)
• Window Switch - Warranty (10/4/2016 @191,700)
• Used Cylinder head- Machined [Elgin Super] (02/2017 @ 193,100)
○ Head gasket set {Fel-Pro} [Ebay] (02/2017 @ 193,100)
• Freeze Plugs - Brass {Sealed Power} {ebay] (02/2017 @ 193,100)
• Engine mounts {Anchor} [Amazon] (02/2017 @ 193,100)
• Oil Filter Adaptor O-Ring {Fel-Pro} [Ebay] (02/2017 @ 193,100)
• PCV fittings and Grommets {Dorman} [Advanced](02/2017 @ 193,100)
• Full Synthetic Oil Change 10w-30 {Castrol}[Advanced] (02/2017 @ 193,100)
• Lucas Oil Stabilizer {Lucas}[Advanced](02/2017 @ 193,100)
• 136 Amp Alternator Upgrade {Ac Delco(New)}[Amazon] (03/14/2017 @ 193,300)
New Drive Belt {Mopar}[Amazon](03/14/2017 @ 193,300)

XJRed96

The Alternator was a bigger PITA than expected. Mostly due to my stubbornness of not removing the Alternator bracket from the car. Had I have just done that probably would have saved a good hour of aggravated grinding and test fitting in the car. But I was determined after I had started grinding on the car to complete the task that way. Next time I wont. Also now that I know what exactly needs to be ground and how much, I'm sure the next time I do this it would be a much smoother experience. Since I'm not really running any accessories at this point I haven't upgraded the battery cables yet but that will be my next little project. Likely 4 Ga Cables.

XJRed96

Powerstop Ceramic Pads (red) and Rotors


Finally got around to installing the front pads and Rotors that I've had sitting around since November. They are from a company called Powerstop that I was turned on to by a customer who had us put them on his Acura RL. They are available on Amazon almost exclusively. As with any ceramic Brake pad the cold stopping has no change but the higher speed stops and repeated hard stops are considerably better. I got them because I was getting heavy brake fade while towing my boat, I'm excited to get the trailer on it and see how they work with the extra weight. Also replaced the Slides and Boots (boots were included/ AC Delco slides and bolts)

I've also finally replace the rear diff pinion seal and the Blower motor resistor with a new harness to replace the melted one that was in there.

• New Drive Belt {Mopar}[Amazon](03/14/2017 @ 193,300)
• Blower Motor Resistor and Harness {APDTY}[AMZN](04/29/2017 @ 193,300)
• Rear Axle Pinion Seal {Fel-Pro}[Ebay] (04/29/2017@ 193,300)
• Rear View mirror Auto Dimming{Jeep}[2000 GC] (04/29/2017)
• Front Pads and Rotors {Powerstop}[Amazon] (05/3/2017 @ 193,380)
• Front Brake Slides {AC Delco}[Amazon]( 05/03/2017 @ 193,380)