Alright folks, a lot has happened but I'll try to keep it short.

I finished the rear end and realized I had some extra diff whirring so I decided I would be opening it again to switch out the crush sleeve and try again on pinion preload. Before that tho I was going to start attacking the front end while waiting for new sleeve to get shipped.

For the front end I was littered with logistical troubles. I thought I got a great deal on this used ARB locker but the downside to getting a used one is that there are install shims and **** that come new in box that is just hard to source properly a la carte. So that mixed in with me accidentally ordering a yukon gear set for Low Pinion D30 i was stuck with my front end apart waiting for more things to trickle in the mail to get going

Besides the parts clown show the install went pretty smooth. I was nervous about the shims and getting things tight enough but it turned out to not be a big deal and it was easier IMO than dealing with the rear. More head room too with the steering out.

Speaking of steering... I found some one ton heim steering for $50 on FB marketplace. Could NOT pass up that deal, I also bought some brand new knuckles from him that were pre reamed so I only had to drill out the pitman arm, also grabbed his unit bearing as mine weren't as shiny.


ARB compressor fit snug next to brake booster


New vs old knuckle, accidentally bashed out lower bj on one of the knuckles so had to replace


Almost final ARB install, the line got trimmed a bit


Switch fit great in the housing but too big for the bezel lol - nothing the bench grinder couldn't fix - shortened the switch cover


Front Locker Solenoid Switch install under kill switch arm button


new unit bearings after i had installed onoes but realiezed I forgot the backing plates - DOH!


Tires back on after weeks


Better look at the steering, PO gave me color code for paint so I matched the ARB cover - i don't like red...

More to update but this was getting long...

enjoyed your build thread.
I JUST helped #2 move from east coast to "Denver Area" this weekend.
#1 moved there 2 years ago,, #3 is moving to WY in August

Glad you're enjoying! Changing it up is what it's all about! When are you moving this way?

Break from the wrenching to post a few photos from the r/cherokeexj discord meetup in CO last weeekend. Anyone feel free to come join us on discord - we're a chill group and pretty active https://discord.gg/dwTR6AKk

I have loved the west all my life and always dreamed of moving there. But after building a small business on the east coast for 20 years and living on a "homestead" my wife, kids and I built, I dont think I could ever move.
Wife and I fly out 4-6 times a year.

I AM thinking about wrapping up my 2001 XJ build and leaving it out there at one of my kids, Then when I fly out I can hop in it and go for a week on the "loop" - up eastern WY in the black hills, up through MT, head west, and back down through Yellow stone, Jackson, Medicine Bow.
When I get it out there I'll look you up for some wheeling/fishing

I am going to be setting up a 8.25 in the next week or 2,,
Curious about the whine? Are you sure it's pinion bearing/preload? What/how did you set preload on the initial install?

I have installed LSD and lockers in Chrysler rears with the threaded carrier adjusters (not full gear installs) ,, I assumed the carrier adjusters were WAY easier then dealing with carrier shims, case spreaders, etc??

I confirmed with Yukon that my pinion depth was too deep and this caused the whine. This and apparently going to hard on the break in caused me to ruin the gear set. I'm basically on borrowed time with it now but haave another gear set to slep in there soon. I'm going to email them my pattern before buttoning everything up next time. I found that I preferred the shims over the adjusters. The adjusters seem peachy if the axle housing is sitting on your bench but when you are ducking under the gas tank and trying to shove the carrier, races and adjusters in at the same time you have to balance everything and get the threads lined up it's pretty miserable. You also have to do 25 laps around the jeep to get backlash set correctly. Just my opinion tho. Good luck sorry for the late response

I'm falling way behind here keeping everyone updated, I'm working on the Jeep every day. Sometimes backwards progress it seems. Before we get into the next phase of upgrades I've been doing/going to do I wanted to let everyone know that I had an accident while working on the jeep after I finished the gears. It's embarrassing and stupid but hopefully everyone will take this as a safety PSA. In a nut shell I hastily pulled the rear DS without chocking my wheels. I got out from underneath but tried to stop the jeep by grabbing the tire... which grabbed me and proceeded to crush my wrist and pull my shoulder and head under the rear wheel. An interesting perspective I assure you. Overall it could have been way worse and I'm quite lucky I got away with stitches and a cast. Blood sweat and tears for real... I'm so far behind that i'm basically completely healed at this point but from the get go I have always put the good bad and ugly in this build thread and hopefully you will take my mistakes and skip making them yourself. Lots of updates coming soon

Oh man! Sorry to hear about that accident. These things happen to everyone. Glad you're alright. It's been really admirable how you've taken this jeep back from the dead. I can't believe you saved it with that much rust. Looks like you've learned a lot of skills on the way too.

Thanks mang, live and learn! If you like seeing rust repair you're in for a treat come fall. I have some rot in the rear frame I need to deal with and we'll be pulling the tank and cleaning up the whole rear end. Stay Tuned!

While we're on the subject, I did a couple things while I had the cast on the wrist. Ya know, one handed jobs... Let's just list these rapid fire

I've had the h4 housings for a while but the stock bulbs that came with them were too weak for my taste, I upgraded to these 100/80W Bulbs hot hot hot!



I also upgraded to an actual toolbox/cart. It's meh but better than laying my tools on the floor or a rack



Anyone else under the bezel look like this? So much wire. Mostly Ham radio, kill switch and now compressor/locker wiring. You can see the new locker switch installed below my KILL button on the top left.



I finally upgraded the speedo gear in the 231. I had 31's and this gear is for 33's which I don't have either whoops. Oh well.

I accidentally posted twice and idk how to delete so keep scrolling

Okay back to the fun stuff...

Next up was fender flares. A few months ago I scored some brand new Napiers on marketplace for cheap. I watched the in depth video bleepinjeep did and promptly ignored most of the advice. They are quite forgiving as long as you don't cut TOO much material off but definitely eye ballable. Which is my thing so I'm glad they came out niceish, don't look too close.



Been ignoring this for a while, i cut it all out..



Cut this out too



Maybe a bit too much...



Did my first welding on the jeep and it turned out good.



Starting in on my first one thinking I would do it the right way...



Finished up after giving up on reading the directions.



Took a hiatus after finishing the fronts and went in the back country with my fam



Finished up the rears



35s =] Not psyched that the km3s don't have white lettering tho

So my AC has never really worked. I've charged it a couple times and had ac for a week at most. I was recently gifted a new ac hose so I slapped that one and refilled to no avail. I have had dye in the system before and we all know where it's leaking... so here we go.



'nuff said



Forgive me lord for I have sinned



Leak wasn't as obvious as I thought it would be but the styrofoam was clearly soaked in the UV dye



Repenting a bit



Laid down some noico deadening material as well as some CCF for insulation. I have been getting a lot of heat from the exhaust, figured it couldn't hurt...



Engine quit on me on the first real test drive... was getting no bus and no start... got it towed home bc all i could think was pinched wire or forgotten ground but my kill switch actually shorted and the fuel pump relay was on the same fuse as engine controller. So lucky me!

My buddy and I agreed on trading labor. He's welding up some sliders that we designed together and I get to install his evap core. Fine with me!



This is how she is running with 35s, speedo reads a hair fast maybe 3-4mph



Lining up the square tube



Bender Rodriguez



Finished



Painted and mounted. Design came out better than imagined what do you think?