Considering building a XJ for daily driving and driving the Rubicon (I live near Carson City, NV). I have mechanical skills and have worked on several other models of Jeep so this will mostly be DIY.
I am requesting help with putting one together "right" the first time.

1. What would be the recommended year
2. Automatic or manual
3. TJ/JK Rubicon Dana 44 front axle with 1 ton steering
4. Dana 44/Ford 8.8/Dana 60 rear axle
5. Considering 4.7L stroker
6. TJ/JK Rubicon Rock Trac t-case (4:1)
7. Gearing for 35" tires
8. Quality aftermarket bumpers
9. Suspension lift

Thanks in advance, looking forward to your replies

 

1 97-99
2 Auto - easier on rocks and less maintenance
3 If you're not going over 35s stick with a built D30. TJ 44 is worthless as the weak point of the D30s and TJ 44s both share the same parts. Wagoneer 44s are stonger and stock width but are LP44s if you're worried and want to build a stronger than D30 axle without much work.
4 BleepinJeep is running 42" stickies with wagonner 44s on his Scorpion Crawler with no issues so far. JK44s are the strongest 44s yet if you want to find a rubicon set to swap and build up (they have weak tube so trusses are necessary)
5 Stroke em if ya want
6 It's been done, $$$
7 4.56 for highway and occasional crawling/ 4.88 for heavier crawling less highways
8 JCR, Filthy Addictions Offroad, Dirt Bound, TNT
9 Anything 4.5"+ will want long arms. Avoid RC Offroad

 

Thanks for the information

 

1. If you dont want a computer to deal with then 87 to 95
2. Auto is best. Dana 44 front and Ford 9 out of an early model f150 if youre into fabbing.
3. Dana 44 front and Ford 9 out of an early model f150 if youre into fabbing.
4 - 9 follow unidentifiedbomb

 

If you need help with that build, let me know. I'm in the area.

 

91-99 are all good years. Auto or manual is personal preference, I am a manual transmission guy but the AW4 autos in the XJs are very good and I haven't had any problems with mine. A Dana 30 and Chrysler 8.25 can handle 35s pretty well I went with 4.56 gears because of how small the pinion gear on the Dana 30 is if you go with 4.88s or lower.

 

Don't forget 2 or 4 door....again, personal preference

 

It's 4 doors for me, if I wanted 2 doors I would get a Bronco.

 

2 doors are cool. I love mine. But they can make rear bench access a pain.

 

Not for me...it'd be a Ramcharger......oh wait....been there done that 5 times.......

 

Glad you posted this, prevented me from doing the same. Welcome to the site from a fellow newbie

 

NEWB from the area. Might see you out there. I drive an 89 with matching dents passenger and rear under the rear doors (4 door model) and an EFPH sticker on the rear.

Pick whatever year you find cheap.
Automatic.
1 ton axles.
6" suspension. People talk **** about Rough Country but if it gets you there it gets you there.
Bumpers...Dr. Smash. Support your local builder. His shop is up by the dump. He can build you some sweet bumper and if you ever want it changed the builder is in town.

Between the transfer case, building a Dana 30 and having skills, I'd just go straight to a set of 1 ton axles. There are super duty axles on craigslist for $1200. Sacramento has a new JK D44 axle for $1500 for the rear, and that's just ONE axle. Price out a set of chromoly axles, front locker, and compare it to the price of a super duty Dana 60. If you're going to swap axles and need custom suspension just do it once. The transfer case you want is going for around $1,500 and I priced out a new Atlas 4 speed for like $2,700. Yeah it's almost double the price but you get a LOT more than just 4:1. I found a fully built (air locker, 30 spline axles with new seals, 3.73 gears) and the guy wanted $1,200. It's still weaker than a $1,000 Dana 60.

https://sfbay.craigslist.org/eby/pts...968752759.html
It's been for sale over a month. I just haven't pulled the trigger to buy this. It would be great if I could get this home, weld up what I needed to and get this rolling under my XJ. You can't even buy Dana 30 axles for this price.

 

I like my 2 door XJ, easier to park in store lots, but dream truck is either a 77 or 78 Ramcharger. My dad had a 78 W200, put over 400,000 miles on it before the rust termites got it. You can't kill them.

 

But those Jeeps have a computer.