I picked up a '96 Jeep Cherokee last night. It needs a little work, but not all that much.

Specs:
1996 Jeep Cherokee Sport (XJ)
4.0L Inline 6 cylinder
Automatic Transmission
Manual Transfer case
Dana 30 Front Axle w/ 3.73 gears
Chrysler 8.25 Rear Axle w/ 3.73 gears
33x12.50x15 Mastercraft M/T's (less than 200 miles on them)


Plans:
1. Remove the 3.5" lift kit and install a 6.5" lift kit
2. Fix the knock in the head
3. Clean it up a bit
4. Remove the TJ fender flares
5. Wheel the hell out of it

I still need to find a 16'x6' cheap trailer to haul it on when I go wheeling. Hopefully I can pick one up for $1,000 or less with dual axles and brakes.

Here are the only pictures I have of it as of now.







Welp, I had to pull the motor today. It sure is a good thing I took the day off. It broke either a wrist pin or rod in the # 6 cylinder.

Needless to say it was interesting yanking out that old beast.

I should be picking up its replacement either Friday or Saturday.


My brother trying to separate the engine and the transmission.

 

How come you are gonna remove the TJ flares? Do they rub or do you just not like the look?

 

I didn't like the look of them.

 

i wanna see some pictures when you get in that motor more!

 

Well I found the culprit. It was a piston. The #6 piston blew apart. The rod and wrist pin is still in tack and in good shape.





I picked up a used 4.0 from a local junk yard for $450. It has a 30 day warranty so hopefully it will last and run.





I put a new water pump and thermostat on it before going into the Cherokee.




Going in was easier than coming out. Once the radiator was out of the way, she fell in place.








I took all the A/C items out except the pump. I am going to make the pump into an air compressor and mount a tank in the rear cargo area.


I got everything ready to go except for a power steering pump and a heater hose. I broke off one of the nipples on the power steering pump, so I have to put a new one in. It should be at the parts store today, so hopefully she runs today.

 

It's definitely coming along. I am ready to test her out for sure. It probably will be a local wheeling spot in case something isn't quit right with it.

She fired right up today after I got the last few items buttoned up.

I was worried when she first started because there was white smoke coming out of the exhaust. After letting it warm up and a trip around the block, the smoke stopped. I think it was left over coolant and oil that was setting in the muffler from when the first motor blew it's wad.

The 4"'lift comes off tomorrow after work and the installation of the 6.5" kit begins.

I also need to pick up a set of 15x8 wheels with 3.75 or 4" backspacing. If anyone knows where I can find a good used set, let me know.

 

Well, got the 6.5" lift swap started. I should have the front on and done tomorrow after work.




Here is the difference in the 4.5" springs and the 6.5" springs.




Here is the difference in the stock upper control arms and the Rough Country upper control arms.

 

looking good. how much thread is left in the tubing from the heims tho? You want to be about half way

 

There is about the same amount in the tube. The mounting holes for the new UCA's are the same distance as the stock ones.

 

ok, cool just checking.

 

Got the front on its own weight tonight. I still have to put the shocks, extended brake lines, and sway bar quick disconnects on and the front will be done; well minus an alignment.

 

6.5" on short arms? Gonna be rough riding. Other then that, nice lookin XJ.

 

That is what I have heard. I plan on getting the control arm drop brackets in the near future. I would like long arms, but can't afford them.

 

I got the front buttoned up tonight; well all except for the sway bar disconnect. I can't for the life of me get the stock sway bar end link bolt out that mounts to the frame. I have broke 2 T55 torx sockets trying to get them broke lose. It may come down to grinding the heads off and drilling the bolt out. I do like the way Rough Country designed their sway bar end links with the mount that holds the end link and the sway bar up out of the way when wheeling.

Once it is all on and road worthy, I am going to test the flex out and see if where the extended brake lines meet the hard lines need to be moved down. The lines are the Rubicon Express lines for their 5" kit.





I got started on the rear. I have full replacement springs and shackles for the rear. I am taking the sway bar completely off so I won't have to worry about it on the trail. The bolts are tight as a virgin. I am using a 1/2" drive ratchet & socket with a 4' pipe for a breaker bar. I got the driver side shackle off. That is where I had to stop for the night.

 

Order a Drop bracket kit for the front control arms. It will help with your ride quality.