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Project-XJ...My attempt at an XJ build/revival

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Project-XJ...My attempt at an XJ build/revival

Old 07-23-2012, 10:03 PM
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Default Project-XJ...My attempt at an XJ build/revival

I picked the XJ up from my in laws on a work trip to Pensacola FL. I paid 1000 bucks for it.

I am starting this build/revival thread to document the issues that I either have currently or come across during the process of making this XJ something (whatever it may be). Ill take some more pics when the time is afforded to me. Plus I came across a slick new (to me) camera that I will be using to take the pictures.

Heres the build sheet. Other than the fact that its 2wd its not too bad.


Jeep Cherokee (4x2) (Left Hand Drive) (Cherokee Limited VIN seq. 178146 & above)

Vehicle equipped with: ERH 4.0L Power Tech I-6 / DGS 4-Speed Automatic AW4 Transmission
Built: May 05, 1998


Code Description
*DL Prem Leather Trimmed Bucket Seats
165S Zone 65-New Orleans
1AAS U.S. Dealer Retail
26H Customer Preferred Package 26H
2THA Customer Preferred Package 2TH
3VUA Customer Preferred Discount
610S Florida State Code
910S Florida State Code
A20P 4.0L Engine(ERH)/4Sp Auto Trans(DGS
ADAP Light Group
APAS Monotone Paint
ARTP Classic Decor Group
ASTP Limited Group
AWHP Power Equipment Group
BAUS 117 Amp Alternator
BCDS 500 Amp Maintenance Free Battery
BGAS Power Front Disc/Rear Drum Brakes
-C3 Mist Gray
CACP Low Back Bucket Seats
CBZP Prem Vinyl Door Trim w/Map Pocket
CDBS Reclining Front Seats
CFMS Rear Folding Seat
CGGS Traveling Inboard Seat Belt Buckle
CGWS Next Generation Front Air Bags**
CKAS Carpets - Floor and Cargo Area
CKNS Cargo Compartment Carpet
CKTS Cargo Tie Down Loops
CKXS Plastic Liftgate Trim Panel
CLEP Front & Rear Floor Mats
CSAP Spare Tire Cover
CSCP Cargo Compartment Cover
CSRS Passenger Assist Handles
CSSS Illuminated Rear Assist Handles
CUFS Full Length Floor Console
CUNP Overhead Console
DGB All 4-Speed Automatic Transmissions
DGSS 4-Speed Automatic AW4 Transmission
DHAP Lock-Up Torque Converter
DHSP Floor Mount Automatic Shift Lever
DMDP 3.55 Axle Ratio
DRAS Corporate 8.25 Rear Axle
EAAC All Engines
ERH 4.0L Power Tech I-6 Engine
GALP Deep Tint Sunscreen Glass
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GEEP Deep Tint Sunscreen Liftgate Glass
GFAP Rear Window Defroster
GNAS Rear View Day/Night Mirror
GNCP Sun Visors w/Illum Vanity Mirrors
GTZP Manual Remote Mirrors
GVBC All Vehicles W/Power Mirrors
GXMP Remote Keyless Entry
HAAP Air Conditioning
HGDS Deluxe Insulation Group
JAYP Instrument Cluster w/Tach
JBGP Instrument Panel Woodgrain Bezel
JCDS 100 MPH Primary Speedometer
JHAS Var Intermittent Windshield Wipers
JHBP Rear Window Wiper/Washer
JJAS Cigar Lighter
JJBS Dual Note Electric Horns
JJJS 12V Auxiliary Power Outlet
JPAP Power Windows
JPBP Power Locks
JPSP Power 6-Way Driver Seat
K2RP SRTIPE/BADGE/MOLDING COLOR
K3RS STRIPE/BADGE/MOLDING/COLOR
KAPP RADIANT SILVER - Badge
KBSP STRIPE/BADGE/MOLDING/COLOR
KGPS STRIPE/BADGE/MOLDING/COLOR
KTPS STRIPE/BADGE/MOLDING/COLOR
KYPP STRIPE/BADGE/MOLDING/COLOR
LAJS Headlamps On Warning Chimes
LBBP Courtesy Lamps
LBCS Glove Box Lamp
LDAP Underhood Lamp
LDBP Cargo Compartment Lamp
LHDP Headlamp Off Time Delay
LMAS Halogen Headlamps
LNJ Fog Lamps
LPSS CHMSL Lamp
MBPP Body Color Front Bumper
MBQP Body Color Rear Bumper w/Step Pads
MCAS Front Bumper Guards
MDA Front License Plate Bracket
MFKP Body Color Grille
MHAS Black Windshield Moldings
MMCS Upper Door Frame Moldings
MMGS Belt Moldings
MMKS Body Color Drip Trough Molding
MNAS Black Door Handles
MWGP Roof Rack
NAA Federal Emissions
NBKS EVAP Control System
NFAS 20 Gallon Fuel Tank
NHMP Speed Control
PR4 Flame Red Clear Coat
QR4S Flame Red Clear Coat
RAAC All Radio Equipped Vehicles
RAZ AM/FM Cassette Compact Disc Radio
RCRP 4 Speakers
RDDP Fixed Long Mast Antenna
SBAS Power Rack and Pinion Steering
SCGP Leather Wrapped Steering Wheel
SDAS Normal Duty Suspension
SHAS Front Stabilizer Bar
SHCS Front and Rear Stabilizer Bars
SUAP Tilt Steering Column
TBCS Compact Spare Tire
TBLS Inside Mounted Spare Tire
TRVP P225/70R15 Eagle GA OWL AS Tires
TZAP Goodyear Brand Tires
WJ7P 15X7.0 Luxury Aluminum Wheels
WLZC All Aluminum Wheels
XCYS Delete Remote Start System
XJFS Tethered Fuel Filler Cap
YAAS Build To U.S. Mkt. Specifications
YGFA 8 Additional Gallons of Gas
Z1BS GVW/Payload Rating
ZFJP Spring - Left Front
ZFTP Spring - Left Rear
ZUJP Spring - Right Front
ZUTP Spring - Right Rear
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Old 07-23-2012, 10:05 PM
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Ive named her Project-XJ. I currently dont have any major plans yet because my main project has been my TJ and the XJ was going to be my parts hauler and back up for when the TJ has to go down for another round of mods or repair. Phase 1 for the XJ is mainly making her road worthy/legal in Virginia because she has spent her entire life in Florida and has a plethora of little things that need to be fixed so I can just be legal.

Here are some of the pics.

This was the first pic I was able to get and it was from Google maps of all places. I had to map out my trip back from Pensacola since I happened to go down there on detachment.
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After I got down there I picked it up from a mechanic cause my in laws thought the brakes felt funny. Well the mechaniic "replaced" the front brakes. Apparently he never took it for a drive cause there was a thumping every time you stepped on the brakes. I drove it for a day just trying to find any drivability issues.

The only one was the brake issue. I pulled the driver front wheel and found that the rotor had a bad casting and was thumping because of that.

the bad rotor
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I also wound up replacing both window tracks, motors, and switches on the front doors with JY parts. I now have operable windows.
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I then took her to work one night and noticed that I couldnt see anything because the headlights had 0 reflective coating left so another trip to the parts store netted me 2 brand new headlights. The difference was literally night and day.

Here are the 2 new headlights


The head unit had 2 volume settings off and low. Also the front 2 speakers didnt work. I convinced the wife to let me get a new stereo so I could at least have some tunes and volume control for the 1000 mile drive back. I picked this Sony H/U up for 79 bucks at pep boys. And would you know the front 2 speakers work now. Guess the OEM unit was worse than I thought.

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Here is a quick pic of the JY donor down in Pensacola. It was at Butler u-pull-it. Good people to deal with. They gave military discounts and were able to point me right to it.

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I also decided to bleed as much of the old brake fluid out as I could so I could have fresh fluid. No pics of that but we all know what it looks like.

So then began the 1000 mile journey back home. She was safe enough mechanically to make the trip. Also want to give a big shout out to the Holiday Inn express down there for not wanting to kill me for doing all the work in their parking lot.

Pic from NAS Pensacola at a buoy storage area.
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Topping off the tank as I was leaving
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As I started to leave the gas station my check gauges light came on and said I had no oil pressure. Awesome way to start. I checked the fluid level and she was actually 2 quarts low even though my in laws said that the oil was just changed. Im guessing they didnt add enought cause there are no leaks on the motor anywhere. So I added the required amount and low and behold I had pressure. Good. So the journey began.

Stopped at South of the Border and took a quick pic
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Got her home with no issues.

And now into the garage with her.
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I noticed that the reverse lights didnt come on so a quick search netted me some info about the NSS. It was pretty easy to take apart and rehab. Granted I had to do it twice because I forgot to clean the contact springs on the arm.

NSS on the workbench.
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After everything was said and done I have reverse lights.
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Old 07-23-2012, 10:09 PM
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Oh and an obligatory pic of the TJ.
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Old 07-23-2012, 10:10 PM
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Got some pics of the work on the exhaust. Ive broken my last cutting disk so Ill have to pick some up tomorrow before any more work can continue.

The cat was rattling a little bit when I left Florida and by the time I got home it sounded like marbles in a tin can.

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Im going to pick up some flameproof paint to clean up the muffler so I dont have to deal with replacing it since it still works and has no holes.
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Old 07-23-2012, 10:10 PM
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Picked up some new front seats for 20 bucks off of craigslist. Just gotta get them cleaned up and then installed.

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Old 07-23-2012, 10:11 PM
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Picked up a catalytic converter from pep boys today. So parts should start making their way onto the Jeep
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Old 07-24-2012, 01:59 AM
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Got a little work done tonight after work. I reinstalled my exhaust down pipe, the tranny crossmember and the cat. Here are some pics of the progress.

The new cat on the workbench


Downpipe and part of the tranny x
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The shiny new cat


Thats where Im leaving off tonight. I still have to cut the old cat off the muffler pipe so I can finish the install.
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Old 08-07-2012, 05:19 PM
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Got a little done today. Mainly a houskeeping day and ordered a new muffler.

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Its so much nicer to have it all cleaned out.

My lil Jeeper helping me out. She loves it.

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A pic of both of them.

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Old 08-07-2012, 05:28 PM
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Still unsure of a direction to take the XJ. If anything it wont be extreme just something like a BB and some decent tires.
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Old 08-08-2012, 01:26 AM
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Got off work a little early tonight so I decided to start pulling the seats so I could swap them. I have a power drivers seat that barely works. Is it simple to rebuild the seat frame that I have or should I poke around a junk yard and try and find a manual seat frame? Im thinking the manual frame would be easier but who knows.

Here is what was left after I got the seat out and what Im working with.
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The worn old seat.
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The seat frame. I know I can clean all the rust off but Im just wondering if I can get the seat actuators cleaned up enough to get functionality out of the seat.
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Reference marks.
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Gonna go figure out my game plan for the frame.
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Old 08-13-2012, 07:46 PM
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Well after a little thinking about the power seat I was able to get the forward and aft controls on the power drivers seat working so I just re-used the frame and got the drivers seat swapped with my craigslist find. I still have to do the passenger seat but that shouldn't take all that long.

New drivers seat
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On to the engine bay. I had part of the fan shroud broken when I picked up the Jeep so I took a piece of sheet metal that I came across, cut it down and cleaned and painted it with some VHT paint.

Here is the hole that needed to be filled.
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The metal cut and drilled to fit.
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Cleaned up and ready for paint.
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Painted
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While I was in the engine bay I decided to paint the valve cover with some left over engine paint.
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Thats about where I am right now. I did get the new muffler installed and now I just have to get the rest of the tailpipe since I believe I cant have a turndown on it.
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Old 08-13-2012, 10:30 PM
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Default quick question...

Hey I saw this thread and nice! I am pretty much doing the same. Trying to get mine up to par mechanically. I'm wondering what type of CAT you bought and where? Is VA a CARB or No-CARB state? I'm stationed up in the Northern VA area and none of the mechanics that I've called and asked has been able to answer this question. Hopefully, you can. I'm trying to buy one online but I don't know which one I need.

And NAS Pensacola? I was there 6 months ago doing upgrades for a ship. I recognized those buoys, lol!
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Old 08-14-2012, 12:14 AM
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My squadron went down there for detachment. I just happened to luck out cause my in laws are there as well. I went down there for school back in 01 and we visited a couple times in the last year. I just like that area cause you can back up whatever your driving and throw a line in the water.

As far as the cat I got a Walker one from Pep boys. Its 49 state legal. Apparently California is overly strict on what will suffice as a replacement. As long as you dont move there permanantly you should be good. Here is a link to the one that I got.

http://www.pepboys.com/parts/exhaust...KEE/0-624240L/

It literally slipped right on once I was able to remove the OEM. It is held in place with an exhaust clamp. I just reused the old one.

Hope this helps.
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Old 08-14-2012, 05:50 PM
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Busted out some odds and ends last night. I managed to break my battery tray where one of the tie down bolts connect to it. I think I have some JB weld floating around in my garage somewhere. Will that hold the plastic?
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Old 08-18-2012, 09:01 PM
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Ok so today the misses gave me about 8 hours to mess with the XJ. I started at the pick n pull. They had an almost complete MJ there thats beggin to be brought home and fixed up. Maybe in my next life.

Ive been looking for that little plastic shroud that goes over the back license plate. The XJ they had at the JY actually had a good one on there so I grabbed it and the shocks for the back hatch.

Heres the score.
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Heres the old plastic trim.
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Heres the new one installed.



The new shocks installed.
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My battery tray repair with quik steel. It worked for what I needed it to do.
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Ive also been trying to troubleshoot my fog lights. After a ton of digging around the front end of the Jeep and pulling both fogs out so it would pass state inspection I thought about changing the relays, so I swapped the relays and still had no luck. Took my Fluke to the PDC and had good voltage there. So into the drivers seat. Long story short I pulled the switch out and checked for voltage at the switch which I had so I took the switch apart and noticed that it was corroded. I didn't get any pics of the initial dis assembly but all I really did was just clean all the contacts inside the switch with a wire brush. Re-assemble with some dielectric grease and voila.

The switch taken down.
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Cleaning the contacts.


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Also got the final measurements for the rest of the tail pipe. Hopefully tomorrow I can get the last couple pieces and then get her put together and inspected.

Fingers Crossed!!!

Last edited by BomberJeep; 08-18-2012 at 09:08 PM.
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