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92 2 door XJ budget daily/weekend wheeler build

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Old Nov 19, 2016 | 04:05 PM
  #46  
BC.Bryan92xj's Avatar
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From: Comox, BC, Canada
Year: 1992
Model: Cherokee
Engine: 4.0L
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Well kind of a random buy, but picked up some 33s! Same tire as before just bigger. 33x12.5R15 BFGoodrich MT KM1. They sure fill up the wheel well! Have to cut my fenders before I go wheeling for sure. Front rubs hard just turning tighter.
Think I'm just cut and folding the rear with no flare, but a 18x12 mudflap to keep the cops happy. Upfront just cut and then mount a rear TJ flare until I can make metal flat flares.



Have to make it work to get them home!



33s beside the 31s



33s are on!
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Old Nov 20, 2016 | 09:30 AM
  #47  
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From: Colorado
Year: 1991 2-Door
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Engine: 4.0 liter
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Nice! I can't wait to get 33"s for my rig. When I bought it the P.O. had some generic 33"s on it. But without gearing for them plus a Dana 35 I opted to take for 31"s. Do you have bump stops? When I get 33's I will have to add a hockey puck to mine.
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Old Nov 20, 2016 | 09:33 AM
  #48  
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From: Comox, BC, Canada
Year: 1992
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Originally Posted by JandDGreens
Nice! I can't wait to get 33"s for my rig. When I bought it the P.O. had some generic 33"s on it. But without gearing for them plus a Dana 35 I opted to take for 31"s. Do you have bump stops? When I get 33's I will have to add a hockey puck to mine.
Thanks! I've got the Adana turdy5 as well with 3.07s now so working on doing the axle swap asap haha. I have 3 hockey pucks per side up front for bumpstops. Rear I just bought new ones and am going to add square tubing underneath to get to the proper bumpstopping. Definitely have to cut the fenders in curtain spots. Going to start out cutting just where I need to, then go from there!
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Old Nov 21, 2016 | 04:14 AM
  #49  
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From: Colorado
Year: 1991 2-Door
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Engine: 4.0 liter
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I have another axle swap pending before I splurge on my new tires. With all the work I need to do on my trailer it might not happen as soon as I'd like.

You will like the difference 3.55 gears will make, best thing I have done since I got my XJ. Now I can do trails that I never would have before. And swapping the axles is pretty easy/cheap way of getting there. You really have a good XJ to work with, well worth every penny you invest into it!!!
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Old Nov 21, 2016 | 04:28 AM
  #50  
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From: Colorado
Year: 1991 2-Door
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Engine: 4.0 liter
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Kind of curious, Do you still have the stock brake booster? I went ahead and up-graded to a 95' booster. Stopping with the larger tires was getting pretty sketchy.
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Old Nov 21, 2016 | 12:35 PM
  #51  
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From: Comox, BC, Canada
Year: 1992
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Yeah getting my axles in is definitely going to make me happy! Rear I just need to clean and paint, then assemble. Get the Aussie locker too haha, hoping for a sale to happen on those. Front I still need all the parts but it's already painted haha. Definitely can't wait to see the difference with 3.55s now!

And thanks, it is a good platform to work off! Has it's quirks and flaws but it's a 24 year old XJ, of course it does haha.

I still have the stock brake booster as well. Is the 95' a good upgrade? I haven't found stopping too bad yet, but I haven't had to slam on the brakes or anything.
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Old Nov 22, 2016 | 10:05 AM
  #52  
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From: Colorado
Year: 1991 2-Door
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'95 and '96 are a direct swap no modifying anything except making new lines going from the master cylinder to the proportioning valve. You can purchase a brake line rod about 4' long at O'reilly's That the flares on each end are correct for the master cylinder (or the P-valve?) making it so that you only need to flare the other end. use a coat hanger to mock up a pattern to shape your lines.

Both my sons '94 and my '91 emergency stopping was quite an adventure until we swapped the dual diaphragm booster in. Once we went to larger tires it was even more critical.
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Last edited by JandDGreens; Nov 22, 2016 at 10:10 AM.
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Old Dec 7, 2016 | 12:47 AM
  #53  
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From: Comox, BC, Canada
Year: 1992
Model: Cherokee
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Just went ahead and dropped the money on a locker! Aussie locker for the rear 29 spline Chrysler 8.25. I'm stoked. Rear axle needs to be painted and assembled...should have painted that before the cold weather and snow hit. Front I need basically everything still lol, but it's painted.

Also picked up some rock lights. Kit with 1 for each wheelwell, Bluetooth with app on my phone. Color changing too if I want. Will probably do those this weekend.
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Old Dec 28, 2016 | 09:28 PM
  #54  
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From: Comox, BC, Canada
Year: 1992
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Default Almost ready to go!

Went down and picked up my Aussie locker for the rear C8.25! Stoked on it. Picked up another front D30 too haha. Couldn't say no for $100. Complete from a 97, in good shape. Everything appears to be good to go, so less money to spend right now and that means quicker to getting the axles in! Just need it to warm up some so I can get outside and clean them up, then paint them. Fresh Aussie locker in the box
Fresh Aussie locker ready for install!
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Old Jan 15, 2017 | 12:48 AM
  #55  
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From: Comox, BC, Canada
Year: 1992
Model: Cherokee
Engine: 4.0L
Default Steering box brace

Well my S10 steering box is on its way out unfortunately. Guess the 33s killed it lol. But I've been looking into options that don't cost an absolute fortune, and basically seems that my best bet is a new steering box, still the S10. Along with one of these two braces. Now it sucks being in Canada for things like this because of the exchange and shipping, but don't really have any other reasonable options per say.
This first one is cheaper first off, and direct bolt on, no modification other than needed swaybar drop brackets. It's blue too so that's neat.
http://www.ironman4x4fab.com/Products/SBB-SSS.html

Now this one, it's the more expensive one. It does require some drilling and cutting of the front crossmember/support I believe. Nothing major but just a factor in comparing. It too needs swaybar drop brackets. It has tow points which is sweet, but at the same time I plan to build a bumper this year anyways with tow points. So not super concerned about that. It is super beefy for sure.
http://www.boostwerksengineering.com...Brace_p_8.html

Kind of leaning towards the Ironman 4x4 one, being cheaper and still sturdy. Not really sure. Anyone that sees this have any opinions?
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Old Jan 15, 2017 | 06:43 AM
  #56  
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From: Colorado
Year: 1991 2-Door
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I had that frame failure at the steering box area. So I bought some front stiffeners from Rusty's Off Road and bought a brace that runs from the other frame rail to the bottom of the steering box and called it good. It has held up well for a couple of seasons.
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Old Jan 15, 2017 | 10:43 AM
  #57  
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From: Comox, BC, Canada
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Originally Posted by JandDGreens
I had that frame failure at the steering box area. So I bought some front stiffeners from Rusty's Off Road and bought a brace that runs from the other frame rail to the bottom of the steering box and called it good. It has held up well for a couple of seasons.
Yeah the only issue with that is that it doesn't support the sector shaft so it puts all the force on that and the bushings/bearings around it. That would stop the steering box movement so no cracked frame rails and such, but the ones I posted brace the sector shaft which should save my steering box next time I'd imagine.
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Old Jan 15, 2017 | 07:13 PM
  #58  
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SWEET, I just policed up a "93" 2DR 4.0L that I have plans of modifying for a 2 track truck in MI. So far tires, wheels, LED lights all around, CB w/SSB, roof rack. I really favor the 2 doors, however not sure of the 4.0L. Thanks for a great photo spread.
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Old Jan 15, 2017 | 07:51 PM
  #59  
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From: Comox, BC, Canada
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Originally Posted by PsyopsE6P
SWEET, I just policed up a "93" 2DR 4.0L that I have plans of modifying for a 2 track truck in MI. So far tires, wheels, LED lights all around, CB w/SSB, roof rack. I really favor the 2 doors, however not sure of the 4.0L. Thanks for a great photo spread.
What do you mean by 2 track truck? Not sure haha. But that's sweet! The 4.0L is great too. Love the 2 doors a lot, they look great in my opinion.
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Old Feb 25, 2017 | 10:53 PM
  #60  
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From: Comox, BC, Canada
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Unfortunately not much to update on. Haven't made any progress on the axles aside from gathering a few more parts. Need to powerwash them and everytime I have free time it snows...not the normal for around here. Need to get on it ASAP. Lots of stuff to get done before my hopeful wheeling trip to Whipsaw trail.
It snowed for a week straight when I was supposed to do my axles. Instead I welded on a spare tire mount on my roofbasket and repainted it. Ready rod, some nuts, made a wingnut and just some flatbar on the bottom between crossbars, and the top to hold the wheel down with the wingnut. No more ratchet straps.

My most recent issue, as in solved today, was the Jeep died on me and wouldn't run. Replaced the TPS, IAC, checked CPS, checked for fuel and spark, vacuum leaks, broken wires, etc. Was stumped. Finally figured out it was the fuel pump ballast resistor keeping it front running (suggested by someone to check), and then cleaned the IAC port and using the new one fixed my idle/throttle issues. First time it's let me down in the 2.5? years I've been driving it.
Getting a rooftop tent is also in the works, along with shackle relocation brackets using stock shackles (hoping for no more than 1" lift) and rock sliders! Axles still take priority though, I need this snow to stop (snowing again as I type this, snowfall warning) so I can get the axles cleaned and painted outside.

Last edited by BC.Bryan92xj; Feb 25, 2017 at 10:55 PM.
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