Rlmx

How are the welded in braces holding up? I am doing the same.

YOU ARE MY HERO

Your attention to detail is out of this World.

DustyWagoneer

Thanks!
Yes the door braces are holding up fine.

Well it's been so long since I have had time to do anything to my poor little Jeep.
But a few weeks back on my return from SmellA..................errr I mean LA my clutch master decided to go south, and leak all over my left foot and floor.
So NOW was the time to do the external slave swap, that and to do a proper clutch job on Scarlett I reckon?

A little over a year ago on my way to the FSJ (Full Size Jeep) invasion up in Ouray, CO. unfortunately my Scarlet's Clutch died leaving Flagstaff, AZ. I did manage to make it all the way in to Mancus, CO before I was just like "NOPE! I need to get this fixed mode, I can't drive the whole way without a clutch".

I found this place that had all kinds of Jeep's outside, and I thought to myself "Maybe this place might do me right", OK The quick answer to that question was, yes they put a clutch in but NO! they did sheet work. But hey! I was on vacation right?

Fast forward to recent times.
We were junk yard hunting a few months back and found a 94 2.5L, AX5 Xj. So we proceeded to pull the motor for that bell housing (I also grabbed the computer too, as well as the rear hatch).





My little Scarlett is a 1993, so she had the internal slave cylinder, which as we all know SUCKS!
I had read this article a while back on line the site is Four Wheeler Network. But it was how to do the swap to the 1994 bell housing. http://www.fourwheeler.com/how-to/tr...inder-upgrade/

Seamed easy enough?
One HUGE thing that article left out however.

1994 Jeeps changed from a Bosch starter, to a Mitsubishi starter.
SO when I was bolting things up, the dog gone starter did not fit. Odd?

I went to the McParts store sites and started comparing flywheel's, and starters. The 1993 and 1994 use the same flywheel, however the starters are WAYYYYY different.
So went down the hill, and picked up the newer starter, and yes it fit fine, and even worked when I turned the key. Cool!

So it's pretty straight forward doing the swap. The only thing I did not do ummmmmm right away is buy the Advance Adapters hose and fittings.
I had ordered a CROWN master/slave clutch set up from Qudratec.com, and it had a stainless steel braided hose already installed between the two units...................................
When I opened the box the hose was kinked at the slave end.
I tried bench bleeding it but sure enough it was leaking.

So yesterday I called Advance Adapters, and paid for overnight freight to me (I need this running tomorrow). Everything is working fine now with that expensive.................. errr I mean really well built nice hose.

So Parts for this operation are as follows;

1994 Bell Housing
New Luk Clutch kit
New Flywheel
New Shift fork (one from JY was to far gone)
New Ball Stud for shift fork
New Retaining spring for shift fork
New Front Bearing Retainer for Transmission
Front Input Shaft seal for transmission
Rear Output Seal for transmission
Oil Pan Gasket
Rear Main Seal
New Slave Cylinder
New Master Clutch Cylinder
Advance Adapters Hose and fittings
New Starter
New O2 Sensor
3 Qts Pennzoil Syncromesh oil
1 1/2 QT ATF+4
1 Gal of Castrol 10/40
1 Wix Gold Oil Filter
35 tooth Speedo Gear
1 tube of Right Stuff Gasket Maker



Well onto some more pics:

New Bearing retainer on, old bell housing off. Time to chean this thing up a bit before it goes back in.


Old bell housing with crappy "internal slave cylinder" GOOD FREAKING BUH BYE!



When I looked up at the head on the engine I saw what looked like a whole lotta oil in the freeze plug? Nope JB Weld Putty. YIKES!



All Better!

DustyWagoneer

I am kinda **** retentive, so I wanted to do the rear main seal, and oil pan gasket as well once the flywheel was off.

Glad I had a new seal here, as the old one was weeping as you can see. Also you can see that oil pan gasket looks kinda wonky.







More Better now, PLUS! I now have a shinny oil pan after cleaning it out, and painting it.

O


Ohhhhh! More Shinny! One thing I did not know till I actually read my TSM, is that you are not supposed to resurface a flywheel on these Jeep's. They have a concave surface to them.





The "NEW" Advance Adapters hose, and the fittings already installed into the Master & Slave.






Already to go back in. Of course I scratched the heck outta it putting it back in. Just a note: Take the shifter out before reinstalling the tranny. It makes it easier to get back up there, but also you can fill the transmission from the shifter hole.



All back in. I also took the opportunity to change the fluid in the front D30, and clean and paint the cover. This month is Smog Check, so a new Bosch O2 Sensor was installed too.



Next week I think I will actually install those nice new CORE4x4 control arms and track bar. OH!I also have all the parts now to do the Rear Disc Brake swap, and a complete brake system overhaul.

5-Speed

Looking good Dusty! Keep up the good work.

DustyWagoneer

Been a while I know.

Recently did the ZJ rear brake upgrade (including the ZJ proportioning valve), Plus I replaced the brake booster, master cyl., front calipers, Powerstop front rotors & the Z36 pads, rear Powerstop Z36 brake kit, and all new brake lines.
I knew my rear brakes were not adjusted properly but When I went to start working on the Jeep I found that there was no fluid in the rear master cyl. reservoir, so I had been driving around with no rear brakes for a while with heavy loads in the Jeep!
A little while back I had found a 1994 ZJ in the junk yard, and just figured I would grab the parts of of that on that Jeep to do my disc conversion?
So I had done a TON of research on doing this conversion, after I grabbed the parts I took a snap of the VIN plate on the drivers door for future reference because I remember reading that there was some kind of difference in years?.
In 1994 there are TWO different caliper brackets. The earlier ones use a different set of brake pads, than the later ZJs. I found this out AFTER I had ordered my brake kit from Summit Racing. Thank God I ordered from them, as they just sent me out a second set of pads NC.

The axle on the passenger side was toast when I pulled it, so back online to Summit to order a new one. Before I had found the bad axle I had already decided to do bearings and seals, since the axles would be out to put in the longer ZJ wheel studs.





E brakes installed on sand blasted, and painted parts.



Longer bolts to hold backing plates & Caliper brakets.



Routing of brake lines to rear calipers:





Longer YJ Brake line to axle:



Finally Back together, now on to the passenger side!

Griffyorcono

Holy crap you're alive?!!

DustyWagoneer

Barely alive........................

So soon as I was done with the rear brakes, it was finally time to install the CORE 4x4 control arms and track bar that I had bought a little over a year ago. YEAH YEAH YEAH! What ever!
The other thing I never got around to till now is installing the OME shocks.
OK Truth?
I got tired of moving them around in the garage for the last year, and they were just taking up to much room in the boxes!

So anyway I decided it was time to install those CORE 4x4 parts, besides there was an awful clunk coming from the area around the driverside floorboard, and I just knew that the bushings on the front axle were probably shot? Also I had that crappy track bar drop bracket on the front, and I have NEVER liked those things.
So since I was doing all the brakes, everything was coming off. I did not intend to do the ball joints, but knowing how badly this thing was taken care of prior to me getting my grubs on it I should have just bought them before I started the front?
Yeah they were shot!

I had already installed the control arms, and new shocks before I started this next phase. I dripped brake fluid on my new shocks when I took the master off



Unfortunately the caliper brackets had pretty good grooves in them, so I ended up taking them over to Ronnienofako's shop for a little welding.


Much better now!


New Spicer ball joints, new hubs, blasted caliper knuckles, and shield, then painted.


I did not want to go with the slotted and drilled rotors on the front, I did that to one of my SJ's and ended up with cracked rotors. They just get to hot on a daily, that also wheels.



Installed new spring isolators, and Rubicon extended brake lines.
I also had to do a little grinding on the gusset to the track bar drop bracket. The sway bar was hitting it a bit. You can also see I added JKS disconnects.




Installed the ZJ tie rods, and also installed new draglink.






Did a "driveway" alignment, straightened my steering wheel (nice since it has always been off since I got the Jeep), and dropped her back on the ground.
Really amazing how nice it rides now. The only thing I will say is that the OME sport shocks do ride a little rougher than the Rubicon shocks that were on it.

DustyWagoneer

SO MUCH SPAGHETTI & WEATHERPACK CONNECTORS!






Oh yeah!
And maybe 5 or 6 Carling Contoura V switches too?

DustyWagoneer

Lots and lots of electrical stuff going on!

My lil XJ never came with high falootin stuff in her. In fact she was pretty much BASIC BASE Cherokee from the factory.
But that wont stop me from making her a lil more civilized.

So a while back I bought a roof console for her plus the wire harness that goes down the passenger side A pillar, but the problem is that the poor thing came with out it, so the wiring for the console is not there under the dash.
There was a connector for the Ambient Outside Air Sensor under the radiator, and it does goto one of the main body connectors under the dash. Unfortunately that is as far as it goes. So I have to splice into those wires, and run them over to the passenger side kick panel area.
The first thing I had to do is figure out the pin-out for the OH consoles wires.
Since my Jeep never came with Central Locking, once I figured out those wires I just kinda put them to the side.
So now I am in the process of making my own wire looms to goto the console from the required area sans the central locking system.
Yeah I know it is OVERKILL but I am using Weatherpack connectors for EVERYTHING in my Cherokee.




So now I just have to go buy a few more connectors, terminal pins, and wire seals for the next phase.
Stay tuned more to come!

DustyWagoneer

I finished up the relay pack wiring today, and so far (knock on wood) everything works like it should.
I ended up having to mount the relay pack on the passenger side Kick Panel. I kinda miscalculated just how much space is on the Lower Dash Panel. I think it is fine down there however?

DustyWagoneer

I got done wiring up the Overhead Console yesterday, and all my courtesy lamps lit up just fine. But when I went to test out the Compass / Outside Temperature unit nothing lit up. BUGGAR!
So last night I did a whole bunch of reading to start to fear that the module might be bad. This morning I took it all apart, and sure enough there is some damage to the PCB where the capacitors are.
Back to all the wiring, I used Weatherpack connectors fore everything that I did. The factory connectors are rather hard to get apart without damaging them.

So here is the finished passenger side before I install the lower dash panel.




On the drivers side I cut the two wires for the temp probe outside the Jeep, from one of the main connectors.
I then used a two conductor plug for those wires. After that it runs over to the passenger side to feed the OHC.


So here is the damaged module.
You can see the burned up capacitors above the display.

moonsandals

Good idea with the weatherpack connectors. I do the same.

The blown capacitors is somewhat common. I fixed mine using a multimeter, soldering iron and some new capacitors. I saw a person on eBay doing repairs if that's not your strength.

I have a post somewhere outlying how I fixed it. I'll see if I can find it.

Edit: Here you go. I hope this helps.
https://www.cherokeeforum.com/f46/malcom-light-not-quite-stock-build-240326/index7/#post3563716

DustyWagoneer

Thank you for posting the link to your build thread again. I had forgot that you did a rebuild for your compass/ temp module. That and I was bummed that the pictures on that NAXJA thread were gone. I did read his rebuild thread.
The only thing I have not sourced yet are the SMD's.
Mousser has been hard to obtain parts from as late too.
I found most of the parts (including the micro switches) from an ebay seller, and the electrolytic caps are all of the OEM manufacture.
At this point I need the SMD's, power regulator, and the crystal.

kecurroj

Nice thread and she doesn't look like a pig anymore.

DustyWagoneer

Kinda been taking a break from pretty much everything as late. 2021 has turned out to be pretty sucky just like 2020.........................
Scarlett has been WAYYYYYYYY neglected in the mean time, and she kept giving me the stink eye every time I walked by her, so I finally gave her some lovin this week.


I did get all the interior wiring done for all the rack lights, overhead console, and trailer hitch. Unfortunately I am still waiting on some electronic parts to show up for my temp/compass module in the OH console.

So since I do not have a rear seat in the Jeep anymore, I decided that I could use a few more L-Track tie down points in the cargo area. The few times I have had to move sound equipment around in the Jeep, I found myself wanting more than just those two L-Track strips, so maybe just maybe I am going overboard just a bit?


Drivers side
I used the old seatbelt hole, and mounted a small strip of L-Track in there. I actually drilled through the thin sheet metal, and added a piece of 1/8" plate under it that is tapped to accept the screws. It is very solid!



Passenger Side

I also used the area that the rear seat fastend to on the sides. There is a really nice plate that those torx screws attach to, so I just drilled and tapped them for the mounting screws. I did fab up that plate you see there out of aluminium. It is just fascia anyways.


Floor and passenger




Of course it is mirrored on both sides, I just did not take that many pictures. I figured that maybe some of you would figure this out on your own, but in todays world.................................... There is a whole lota stupid to go around.