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Project Carol, the neglected 2000 Sport

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Project Carol, the neglected 2000 Sport

Old 10-30-2018, 10:08 PM
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Default Project Carol, the neglected 2000 Sport

Hey all,
So i recently bought my first Jeep a 2000 Cherokee Sport 4x4 Auto 4.0. 162k Miles. 5 31" General Grabber AT2's on ZJ wheels
I got her for really cheap and after about a week I really started looking it over.



I knew going in there were the typical rust issues on the rockers and possibly the frame and floors and i was right

Pass floor near trans hump

drivers frame

drivers floor plug

drivers side floor

rear frame small crack and not sure what that is...lol

The rockers are well mostly missing on the pass side, the drivers side isn't as bad but i am gonna try and do it right.

PO tried the spray foam trick

door needs love or just new rear doors

Over all its mostly there, the fenders were cut to make room for the 31's he put on and he did a decent job but i have a lot of work. This isn't my daily driver but i hope it will be some day.


She needs basically every bushing ever except sway bar and end links. She needs ball joints, tie rods, possibly ujoints all fluids done and possibly a heater core, heat takes forever to get warmish... so im gonna try a back flush first.

What is /was this thing?

can see the transfer case, and the rusty looking area where the shaft goes in.

Gunked up bad...lol

PO added one new steel brake line drivers side rear. Rear shocks are probably toast but it seems to ride alright.

Leak, prolly RMS

Chrysler 8.25? Worried the bolts might be deteriorated.

Overall front end

Probably needs leaf springs

Gonna replace it all.

First thing is i want it to be safe, he drove it every day to work and back and it never failed but I wanna make it better.

Other things to do:
Replace the rear lift gate latch as mine wont stay latched after being opened.
Battery cable upgrade
Brakes bled and possible replace
Alignment
RUST REPAIR!
Better radio and speakers.

Possbily a head if mine ever cracks

Things i have done:
FIxed the hatch harness for now until i can replace it or just take the time to fully rebuild it.
Fixed the rear wiper but it is slow as hell.
Cleaned about 20lbs of mud from places mud shouldn't be lol

I know shes not as good of a starting platform as usual but for once i have a car to drive and one to tinker with.
I want it to be a DD and have some decent off road capabilities possibly overland style while staying legal in MASS. at least till we move.

I am all for suggestions / options!

Thanks for looking!

Last edited by 2KMAXJ; 10-30-2018 at 11:43 PM.
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Old 10-31-2018, 11:54 AM
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the rust repair needs to move to the top of your list it looks pretty bad and you may want to find a more solid project(I am from Ohio I feel your rusty pain!!) maybe look for a clean body with a blown motor /trans and use this one for parts
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Old 10-31-2018, 12:36 PM
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Originally Posted by tinytrax78 View Post
the rust repair needs to move to the top of your list it looks pretty bad and you may want to find a more solid project(I am from Ohio I feel your rusty pain!!) maybe look for a clean body with a blown motor /trans and use this one for parts
Probably the best advice, sounds like you're going into complete overhaul mode with this, probably cheaper to buy a better starting point before you're in hip deep. Nice benefit to have a separate DD tho!
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Old 10-31-2018, 01:26 PM
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First off thank you guys for the honesty
I know the rust is bad but it might not be that bad and worse case I can part it out and recoup my.initial investment. I will pull the carpet to assess the destruction and go from there. I'm sure you guys are right but I wanna stay hopeful lol
ryst us top prioruty, a lot of it is that scaly rust and having dealt with it all my life living in New England I'm hoping I can save at least one lol

Last edited by 2KMAXJ; 10-31-2018 at 01:32 PM.
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Old 10-31-2018, 01:41 PM
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NP FYI I just learned that in order to pass MA inspection you need to have the plastic bumper ends on... Odd but apparently they need it to take pics for the state. IDK if you're close to me but I have mine lying around if you need to borrow them for the inspection
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Old 10-31-2018, 02:18 PM
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Originally Posted by ixanay_on-the_exjay View Post
NP FYI I just learned that in order to pass MA inspection you need to have the plastic bumper ends on... Odd but apparently they need it to take pics for the state. IDK if you're close to me but I have mine lying around if you need to borrow them for the inspection
Yeah I just found that out as well I still have them the guy gave them to me when I bought it. Appreciate the offer though. Wouldn't mind hanging out get some fresh eyes on this if ya like. Lemme know

Last edited by 2KMAXJ; 10-31-2018 at 02:22 PM.
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Old 10-31-2018, 09:32 PM
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Funny that I just bought the almost exact same XJ! Same color, same model, about the same mileage, and the same condition, although mine is not QUITE as bad rustwise. The first thing I did was have the frame welded wherever it needed to be to make it safe. My mechanic spent 13 hours on it and it looks solid! He wound up charging me $1050 just for the welding and I know he padded the bill so it wouldn't bite so much.

My work is a little ahead of you because the PO has already replaced the steering linkage ends, ball joints, and wheel bearing. I'd send you a picture, but I don't want to clog up your build thread. I now have a completely new braking system except for the brake booster, master cylinder, and rear drums. Even the rubber hoses and brake pipes are new.

Last edited by dave1123; 10-31-2018 at 09:41 PM.
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Old 10-31-2018, 10:01 PM
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Originally Posted by dave1123 View Post
Funny that I just bought the almost exact same XJ! Same color, same model, about the same mileage, and the same condition, although mine is not QUITE as bad rustwise. The first thing I did was have the frame welded wherever it needed to be to make it safe. My mechanic spent 13 hours on it and it looks solid! He wound up charging me $1050 just for the welding and I know he padded the bill so it wouldn't bite so much.

My work is a little ahead of you because the PO has already replaced the steering linkage ends, ball joints, and wheel bearing. I'd send you a picture, but I don't want to clog up your build thread.
Thanks for the heads up Dave, i appreciate it. I am learning to weld and this will be partly my test for non life saving parts...lol I will have the frame done right, i can tackle the floors/ rockers.
This list is long on this one but i am excited.

I don't mind pics especially if its helps me reference things. I don't know what half this stuff is due to rust...lol Post away

Onto tools i need (putting it here for a reference)

RUST REPAIR:
Die Grinder
Welder
Compressor (borrowing Dad's till i can get a good one)
Air chisel
Air ratchet
Air grinder /sander (the small one)
flappy sanding wheels / discs
primer
seam sealer
Bed liner (i am considering doing the whole floor in this after i seal it and such and leaving the carpet out)
spare metal just in case
rivet gun and rivets
fibergalss bondo just in case

If I'm missing anything let me know
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Old 11-01-2018, 07:35 AM
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The rust is "That bad"
Your frame rail are gone in areas, even the rear diff cover/bolts are questionable.
You could work at McDomalds for min wage and buy a rust free roller, and have about 1/1000 the time it would take to repair that uni body.
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Old 11-01-2018, 07:38 AM
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Ooof... Looking at pictures this is barely even a parts jeep. Between all the front end work your going to need and the heavily rusted frame its going to be a very costly repair bill.

That one rocker looks like someone stuff a blanket in it.
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Old 11-01-2018, 07:51 PM
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So I am gonan go ahead with this as it is , while looking for a possible roller one, my area is slim and I am not made of cash. What i do want to do is learn to weld so i figure this is a good way to start and besides i have seen much worse frames on here get fixed. Peep's jeep comes to mind.

With that said and i do appreciate the honesty, i crawled under and went a pokin and tapping and got this as a result:

Gotta clear it out and see how far it goes

Patch 6 inches out from either end, to good metal should be sufficient

As far as the front end is concerned I will be doing the work my self as i do know mechanics, besides i could always transfer everything over if i do find a less rusty option.

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Old 11-01-2018, 08:42 PM
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Please do not drive it ! That isnít safe to drive . Also I would part it out and scrap that body it isnít worth fixing or pull the drivetrain and find one that needs an engine or trans etc .
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Old 11-01-2018, 09:24 PM
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Originally Posted by 2KMAXJ View Post
So I am gonan go ahead with this as it is , while looking for a possible roller one, my area is slim and I am not made of cash. What i do want to do is learn to weld so i figure this is a good way to start and besides i have seen much worse frames on here get fixed. Peep's jeep comes to mind.

With that said and i do appreciate the honesty, i crawled under and went a pokin and tapping and got this as a result:
This will be a hard and expensive lesson. You say you don't have much cash... I don't think you realize the costs ahead for this in any way.

We are not trying to deter you in any way, but that vehicle is not safe in so many ways that it scares me to think someone wants to drive it.
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Old 11-01-2018, 09:27 PM
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Originally Posted by GreaseMonkey17 View Post
Please do not drive it ! That isnít safe to drive . Also I would part it out and scrap that body it isnít worth fixing or pull the drivetrain and find one that needs an engine or trans etc .
Originally Posted by firebane View Post
This will be a hard and expensive lesson. You say you don't have much cash... I don't think you realize the costs ahead for this in any way.

We are not trying to deter you in any way, but that vehicle is not safe in so many ways that it scares me to think someone wants to drive it.
Yeah i am seeing this now, guess i will just have to part it out and start over. Sucks but life is life.
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Old 11-01-2018, 09:32 PM
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Sorry but that one should be for parts! You start cutting out the rust to repair you wont have anything left. mother nature and the rust belt got the better of that one!
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