Project Great White - 1997 XJ
CF Veteran
Joined: Apr 2008
Posts: 2,340
Likes: 8
From: Burlington, NC
Year: 1994...mostly...
Model: Cherokee (XJ)
Engine: 4.0L I6 HO, Lot's of Bolt Ons
Lookin good man. Did you fab the truss and mounts for the front 44 or did you buy them? They look great, keep it up.
Thread Starter
Seasoned Member
Joined: Dec 2008
Posts: 371
Likes: 0
Year: 1997
Model: Cherokee
Engine: 4.0
Well i bought the front coil buckets from Rusty's but had to mod them to get them to work. The front truss is a TNT truss that I had to cut the driver's side UCA mount off of because it was welded with an incorrect angle. So I still had to do SOME fab work to get it to go in but not as much as building it from scratch.
Thread Starter
Seasoned Member
Joined: Dec 2008
Posts: 371
Likes: 0
Year: 1997
Model: Cherokee
Engine: 4.0
I was able to get the front truss fully welded up. Brad made a bad *** custom trac bar bracket for it. I welded that beeeatch in place and put a coat of primer on it this past weekend. We're getting close now. I'm going to prime it again tonight and start the black paint! I should have this front axle installed by the weekend and taking the Jeep out for a break-in run this weekend or next. Wish me luck! To be honest... I'm sick of working on it now that boating season is here.
Thread Starter
Seasoned Member
Joined: Dec 2008
Posts: 371
Likes: 0
Year: 1997
Model: Cherokee
Engine: 4.0
I was able to make some more progress last night on the Jeep. I'm supposed to go wheelin this weekend so I'm in a hurry to get this damn thing moving under it's own power again...
I got the new HD tierod installed, the front axle is painted, centered and under the Jeep finally. I installed my 5150 shocks in the front last night too. I also was able to get the drag link connected. No pics yet as I left my camera at home today.
Tonight I should be able to get the trac bar installed. We had to make a custom bracket that raised the mounting point about 4 inches higher than the Rusty's coil buckets allowed for as I wanted my drag link and trac bar as parallel as possible on the same angles to reduce bump steer/death wobble.
I'll should be able to get to the front calipers tonight and get the brakes bled too. Then all I have to do is install the dif cover gasket, tighten it down to spec, fill the front diff with fluid and finish running the front locker cable into the cab. The hole is already drilled for it, all I need to do is route it.
Then finally before I take it wheeling, I have to redo the front mounts for the AJ's offroad sliders. He said he made them for the Rusty's kit but he didn't. I have to cut the front mounts off and make a new mount with a hole in it so that the Rusty's thru-framerail bolt will go through to attach it. Time to do some more welding!
Pics will be posted in the next few days of the Jeep outside of the garage (Hopefully).
woo hoo.
I got the new HD tierod installed, the front axle is painted, centered and under the Jeep finally. I installed my 5150 shocks in the front last night too. I also was able to get the drag link connected. No pics yet as I left my camera at home today.
Tonight I should be able to get the trac bar installed. We had to make a custom bracket that raised the mounting point about 4 inches higher than the Rusty's coil buckets allowed for as I wanted my drag link and trac bar as parallel as possible on the same angles to reduce bump steer/death wobble.
I'll should be able to get to the front calipers tonight and get the brakes bled too. Then all I have to do is install the dif cover gasket, tighten it down to spec, fill the front diff with fluid and finish running the front locker cable into the cab. The hole is already drilled for it, all I need to do is route it.
Then finally before I take it wheeling, I have to redo the front mounts for the AJ's offroad sliders. He said he made them for the Rusty's kit but he didn't. I have to cut the front mounts off and make a new mount with a hole in it so that the Rusty's thru-framerail bolt will go through to attach it. Time to do some more welding!
Pics will be posted in the next few days of the Jeep outside of the garage (Hopefully).
woo hoo.
Thread Starter
Seasoned Member
Joined: Dec 2008
Posts: 371
Likes: 0
Year: 1997
Model: Cherokee
Engine: 4.0
Back to this question. I didn't rotate the inner C's as I had 5 degrees of positive caster as it sat with the pinion spinning freely and a slight angle through out the driveline. We'll be cycling the suspension tomorrow night and putting it on the alignment rack to see where we sit. At full droop, the front drive shaft does bind but I bought limiting straps, just in case we can't correct the pinion angle and eliminate the binding at full axle droop.
Thread Starter
Seasoned Member
Joined: Dec 2008
Posts: 371
Likes: 0
Year: 1997
Model: Cherokee
Engine: 4.0
THE XJ IS DONE! I REPEAT, THE XJ IS DONE!!!
Pics will be coming soon.
Well I mean the axles are under it and it drives and can be wheeled now. Brad and I took it for a spin last night and it drives like a champ. Even with no steering stabilizer.
A few things on the to-do list before I really take it out and beat on it....
- Adjust caster and pinion angle using adjustable UCA's
- Adjust rear locker cable (not engaging)
- Purchase and install steering stablizer
- Fill front diff with Fluid (only had one bottle last night)
- Seal holes for locker cable coming into cab
- Flex the suspension and figure out the length for limit strap brackets
- Install my 4:1 case and 21 spline AW4 tranny (I have to go retrieve both of them now from friends... cough cough)
- Install my Allied Beadlocks
- Tube fenders (going to start them in the next week or two)
- Roll cage
Pics will be coming soon.
Well I mean the axles are under it and it drives and can be wheeled now. Brad and I took it for a spin last night and it drives like a champ. Even with no steering stabilizer.
A few things on the to-do list before I really take it out and beat on it....
- Adjust caster and pinion angle using adjustable UCA's
- Adjust rear locker cable (not engaging)
- Purchase and install steering stablizer
- Fill front diff with Fluid (only had one bottle last night)
- Seal holes for locker cable coming into cab
- Flex the suspension and figure out the length for limit strap brackets
- Install my 4:1 case and 21 spline AW4 tranny (I have to go retrieve both of them now from friends... cough cough)
- Install my Allied Beadlocks
- Tube fenders (going to start them in the next week or two)
- Roll cage


