TECHNICAL FORUMS => Project Builds => Topic started by: Callelle on October 22, 2011, 10:36:38 PM
Title: 1997 Jeep XJ Country
Post by: Callelle on October 22, 2011, 10:36:38 PM
I figured since I finally got my Cherokee back on the road running, Id try and throw up a quick build thread. I will say ahead of time, All of the initial mods were done at East Coast Tire in Batavia. My mechanical knowledge is very limited, and almost everything that is done to it is mostly by friends teaching me along the way. Anyway, on with it. I bought my XJ in '07 when it was only at 38k on it. Its been my daily driver until this coming winter.
In Febuary I'd Finally gotten the funds to start my build. I started with a Superlift 4" Lift kit, 15" Procomp wheels, 31" Maxxis Bighorn Tires, 4 KC daylighters, Magnaflow Cat back exhaust, and K&N Air Filter.
Almost Immediately after I bought JKS quicker disconnects, a Hanson Pre-Runner front winch bumper, and replaced the exhaust with a magnaflow high flow cat and a Flowtech Redhots glass pack (didn't really like the sound of the Magnaflow cat back).
The problems/upgrades that have really hindered me for the past 2-3 months is when I cracked the housing of my transfer case at the summer picnic (giving me the opportunity to upgrade to an SYE).
Since I figured Id have my Jeep on the lift for a while, I decided to get some JKS extended boomerang shackles. Since they are one 1" longer, I thought it would be a good opportunity to remove the lift blocks I had under the springs. The problems started when I broke the oil pump locating tabs on the transfer case from not installing it right. Aside from shipping issues on the new pump housing, I tried removing my old shackles and broke the weld nut on the passenger side. After a few frustrating weeks and a hole in my floor later, some friends of mine and I finally got the transfer case, shackles, and lift blocks taken care of. I also ended up installing new H4 headlights (Housings, Bulbs and harness), 2 Hella driving lamps on my bumper, and a Rusty's transfer case skid plate.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 25, 2011, 03:34:54 PM
Finally got a decent enough day to take a good full view picture of it.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on November 04, 2011, 11:38:16 PM
Been putting together ideas for what I want to do to it next, here's what I have so far.
Winter Projects - LED Interior and Dash lighting - New Stereo and sub - Bed lining cargo area
Major Future projects pending on money - Fix Rockers and instal 2x6 - New Gears, Axle shafts, and Lockers - T&T Customs long arm kit - Rear bumper with spare tire carrier
I haven't decided on what gearing I want to do yet. I'm stuck between 4.10 and 4.56. It's still going to be a summer time daily driver and I think the biggest I'm gonna be running for tires is 33s, which I'm gonna be switching to next set. Also as far as lockers go, I want to end up running ARBs since they are the only selectable for the 8.25. My dilemma on that is whether I want to save and get the ARB right away or if I should run an Aussie in the time being until I get a lot of my other stuff done first.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on November 05, 2011, 06:21:43 AM
Put an Aussie in the rear and save for a selectable in the front. The front selectable can help save your u-joints and axles from breakage. 4.10s for mostly street and some off-road seems like the way to go with 33s.
$0.02
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on November 06, 2011, 06:01:25 PM
4.10s are what I was leaning a bit more towards. As far as lockers go I think I\'m gonna get front and rear Aussies simply because Id like to get on some rocks (and not suck at it) at some point before I win the lottery. I also found a shift controller for the AW4. I\'ve always prefered a manual over a slush box and I really dont like some of the shift points when normally commuting. Plus I think it could help on the rocks since I could lock it into first. Anyone have any thoughts on this?
The one I\'m looking into is the Baja 2 because the rail shifter looks like just a tiny switch that would be to finicky to deal with.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on November 07, 2011, 08:33:03 AM
3x6 is huge for rockers, 2x5 11g is the way to go
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on November 07, 2011, 08:38:13 AM
Check my build thread for what 3\"x5\" looks like. I wouldn\'t want to go any wider. I used 3/16\" wall. 11ga would work too.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on November 07, 2011, 10:20:34 AM
http://www.cherokeeforum.com/f58/another-2x6-tube-rocker-build-107100/ This was the thread I was getting my idea from
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on November 07, 2011, 11:19:52 AM
Unbased opinion (having never rock-crawled an auto): I don\'t think a shift controller will make any difference without a very low crawl ratio. Others here have wheeled autos and never complained about the trans shifting out of first. You\'ll be 2-footing it over obstacles until you get a decent low range anyway.
Lockers are nice to have but you\'d be very surprised how far you can get without any or with just one. Don\'t be in a rush. Wheel, upgrade, wheel, upgrade. etc. It will make you a better driver.
Bottom line = get out and wheel often.
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on November 07, 2011, 11:54:59 AM
Quote
Don\'t be in a rush. Wheel, upgrade, wheel, upgrade. etc. It will make you a better driver.
Bottom line = get out and wheel often.
Great advice. I don\'t regret a single upgrade I\'ve made in the last couple years, but wish I spent more time wheeling than building sometimes.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on November 07, 2011, 12:29:21 PM
Quote
Wingman wrote: Unbased opinion (having never rock-crawled an auto): I don\'t think a shift controller will make any difference without a very low crawl ratio. Others here have wheeled autos and never complained about the trans shifting out of first. You\'ll be 2-footing it over obstacles until you get a decent low range anyway.
Lockers are nice to have but you\'d be very surprised how far you can get without any or with just one. Don\'t be in a rush. Wheel, upgrade, wheel, upgrade. etc. It will make you a better driver.
Bottom line = get out and wheel often.
I didn\'t just want the shift control when wheeling. I wanted it for on road driving do. I hate when I\'m starting to go up a bit of an incline and I just give it a little bit of gas to maintain my speed and It drops it right to second. There\'s no need for it and its like my AW4 completely denies the existence of third when its in over drive. Like I said originally, I don\'t like slush boxes. But swapping to an AX15 is way beyond my skill level. Plus I know the AW4 is a strong reliable box. So I\'m gonna settle for the next best thing. And I love to get out and wheel as often as I can. I tried my hardest to get down to Rausch Creek at least once this year. But a lot of family stuff got dumped on me all at once. That and the crack in my transfer case from the picnic had me down for about two and a half months. But I learned a lot from the trips I did go on. The transfer case and my crushed passenger side rockers taught me that. And the fact that a locker is on the top of my major to do list. I appreciate the feed back through ^_^
Title: Re: 1997 Jeep XJ Country
Post by: etk300ex on November 08, 2011, 08:17:56 AM
Its a very well known product in the toyota world as the the aw4 is the same guts as a a340, never heard a complaint. Troy has one I do believe.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 13, 2012, 02:40:00 PM
So I've got a bit of money saved together and my XJ is already up on the lift, just begging to get worked on. Ive decided on getting a locker. After the summer picnic I really saw what a difference it would have made. I've decided on an Aussie after talking to Bill and I'm kind of leaning twords a rear locker. I know it's not really necessary on 31's but I also want to get upgraded shafts for the axle I put it in. I don't really know if anyone has a preference over what company makes better shafts than others but I was looking into Yukons. I also don't really know where to buy them, Yukon's site says the closest place is Gevo's Rears & Gears out in Seneca Falls, but I can get both rear shafts shipped for about $275. Is there anything else I would end up needing other than the locker and shafts? Also, having never taken an axle apart before or doing anything to a dif other than taking off and replacing the cover. Is this something that is easy enough that I'd be able to / should do (considering I'd probobly just be going off of a Haynes manual and the internet)?
Title: Re: 1997 Jeep XJ Country
Post by: AWL4928 on January 13, 2012, 04:03:09 PM
If you haven't purchased the locker yet I would consider doing the front instead. I put one in on My jk and it has been a major increase in the wheeling ability. Also because there is no power to the front axle on the street its like its not there.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 13, 2012, 04:14:58 PM
The reason I don't want to do the front is because of the fact that I want to upgrade the axle shafts at the same time. I don't have the money from chromoly front shafts (from what Ive seen they are 600 - 1000 dollars). And from what I've read, XJs with a rear locker is fine on the street.
Title: 1997 Jeep XJ Country
Post by: MrMindless on January 13, 2012, 04:24:03 PM
I'd second front locker first. And on 31s even locked I don't think you could break a stock shaft if you tried.
My 2¢
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 13, 2012, 04:39:45 PM
I'm also planing on going to 33's but I'm sure the D30 could even handle that. The reason I'm so keen on doing the shafts at the same time is more of a precaution. I understand that shit happens and parts break, but seeing as how I've never even removed a shaft before, I'd like to try and avoid that situation and having to say "Ok, who's going to show me how to do this".
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 13, 2012, 09:43:40 PM
What are the advantages / disadvantages of having the front locked compared to the rear?
Title: 1997 Jeep XJ Country
Post by: MrMindless on January 13, 2012, 10:25:48 PM
I like front traction better. Also when not in 4x4 you'll NEVER know a front locker is there.
Downside: a locked front will tend strongly to push, especially in winter driving. To the point that I believe Bill suggests not running on the street in ice& snow in 4x4 with a front locker.
Title: Re: 1997 Jeep XJ Country
Post by: AWL4928 on January 14, 2012, 12:48:39 AM
Having just gotten to use My front in snow it is not bad at all. It's a little bit of a learning curve but you get the feel for it in like a half hour and don't notice a difference. Just make sure there's enough on the ground to actually need it otherwise it gets funky. And I wouldn't worry about shafts. I'm on 33s still fine and you can deffinately get an extra set of stock shafts for yours at s junk yard just incase unfilled you have money for Chromolly if you still want them.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 14, 2012, 07:17:38 AM
I don't really plan on driving my XJ in winter so I'm not that concerned about it. Having spent most of the night browsing through Jeepforums, I haven't really been able to find much about what either locker does for you off road. The only things I found were that a front locker will pull you up over obstacles, while the rear works really well with a Cherokee because it's a longer wheel base and when climbing stuff the weight transfer keeps the rear wheels planted. Some people swore by doing the rear first and others swore by doing the front first.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on January 14, 2012, 08:23:13 AM
I vote rear.
You need the locker most often when climbing obstacles. If in the front, it may help the front wheels climb but then the weight transfer goes rear. The front may help pull some but with the weight on the rear, that is where I want my traction device.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 14, 2012, 10:22:08 AM
You need the locker most often when climbing obstacles. If in the front, it may help the front wheels climb but then the weight transfer goes rear. The front may help pull some but with the weight on the rear, that is where I want my traction device.
That's pretty much what I read that made me want to do the rear in the first place.
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on January 15, 2012, 02:03:53 PM
front first.. see how amazing it is and them pony up and put a selectable in the rear.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 15, 2012, 02:23:34 PM
There is no selectable for the 8.25 other than an ARB. I've mulled over the idea of swapping an 8.8, but I just dont have the money to do that at the moment.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on January 16, 2012, 08:58:23 AM
time to flip a coin... ;D
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on January 16, 2012, 09:42:54 AM
front first
if you cant get half your jeep over the rock or log, you cant successively "bump" the rear over with increasing amounts of rolling throttle.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 16, 2012, 12:58:45 PM
It honestly might just come down to that. There will be no downside no matter which I choose to do really.
D30 + Pulls up on to obstacles + Invisible on Road
8.25 +Rear tends to lift a tire first +Weight transfer on climbs +Cheaper to upgrade axle shafts at same time (and gives me spares)
I'm still leaning twords doing the rear first and then running a selectable up front in the future. If there ever came a time where I would need to drive it in the winter, I'd rather not have the front fully locked when I used 4 wheel drive. A lot of it still comes down to upgrading the shafts too. I know that with 31s and eventually 33s that I dont really need upgraded shafts, but I've always had the "I'd rather have it and not need it than need it and not have it" mentality. Another thing is sort of "project management". Since I'm pretty much deciding on running a selectable front where its a more involved instal than an Aussie, that would be the perfect time to re-gear and upgrade the rest of the front axle.
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on January 16, 2012, 08:35:29 PM
There is no selectable for the 8.25 other than an ARB.
well thats a selectable for the rear!!!
When I have the money for it some day >.<
Title: Re: 1997 Jeep XJ Country
Post by: jACeL86 on January 17, 2012, 08:04:37 AM
I'm not sure if some vehicles respond differently to placement of the locker, but I'll throw my vote in with Wingman. With just the rear locked in mine I climb just fine and can still steer very easily. When I grab for the front locker as well, I push through corners like I'm on ice. Less stress on the front U-joints as well when open.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 17, 2012, 08:41:57 AM
Alot of what I've read say longer wheel base vehicles tend to do better with the rear between being less noticible on the street and with the weight transfer when climbing. So now that I've decided on doing the rear for sure. I need to figure out where to get my axle shafts from. I was thinking of getting Yukon shafts. Between seeing alot of XJ build threads use them and the fact that there's a place withing driving distance that sells them, it seems like a smart way to go. I honestly have no idea though. I haven't really been able to find a lot that distinguishes them between other manufacturers.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on January 17, 2012, 09:24:22 AM
where is the place within driving distance that sells them?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 17, 2012, 09:29:53 AM
Gevo's Rears and Gears in Seneca Falls. This is at least the closest dealer that Yukon's site says there is to me.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on January 17, 2012, 10:54:04 AM
All the classic car guys use him for their builds. He did the rear of my Yukon XL. Awesome work! Didn't know he was a vendor...
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on January 17, 2012, 05:04:51 PM
anybody can be a vendor.. im a vendor.. just depends on how much you want to pay...
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on January 17, 2012, 05:09:00 PM
side note:
I am very unhappy with a rear automatic locker in my Jeep.. (not the locker.. the locker is great) my suspention is too flexy, motor too torquey, and tires too chirpy...
just my 2 cents.. from years of experience..
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on January 17, 2012, 05:17:34 PM
in fairness - short wheelbase...
aside from parking lot squeal I don't even notice a welded rear in the Dakota.
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on January 17, 2012, 05:36:31 PM
had F and R autos in my XJ and had the same complaint..
also has a lot to do with driving style... just saying.. not for me for something I ENJOY driving on the street...
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 17, 2012, 05:52:14 PM
If I went though Gevo's site, the shafts would be $300 shipped (knock off $33 if I went and got them my self). The only other way it would be cheaper ($30) would be if I ordered it through polyperformance.com. They happen to be who I ordered my bumper and dicked me around and fed me BS for 2 and a half months, so I'd rather avoid them. Are there any places closer that sell Yukon or something comparable for any cheaper?
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on January 18, 2012, 12:50:11 PM
id try Doug at Extreme Axles Sales, only guy i buy axles from. gives it to you straight and everything always shows up.
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on January 19, 2012, 02:03:54 PM
I'll add to the pile of people saying front Aussie in the snow seemed fine to me. Felt very point and shoot, both on and offroad. My rear is welded and I agree with Mindless, squeels occaisionally but nothing very bothersome. I have heard/could see where Aussie's may unload and act weird in the rear. Mine is completely invisible in the front in 2wd.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 19, 2012, 09:06:44 PM
Fender trim / Rear quarter cut and fold (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/s720x720/483686_411436845539024_100000181353873_1802346_1815193149_n.jpg)
I really like the new lines over all. Mike did an awesome job in the M4wd lab. (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/s720x720/416996_411436658872376_100000181353873_1802345_206587032_n.jpg)
Transfer case linkage simplification (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/s720x720/425995_409096315773077_100000181353873_1793646_2074113063_n.jpg)
And today I got my B&M transmission cooler installed (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/s720x720/398988_412279728788069_100000181353873_1804873_2113386691_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: s0l0ithz on March 19, 2012, 09:26:05 PM
Love the new rockers
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 27, 2012, 07:10:39 PM
Went out with a couple friends tonight and found a good sized rock to flex her out on.
This week is going to have a bit of maintenance and upgrades in it. The hood vents, Spicer 760x U Joints (guess I'll finally get to try taking the shafts apart), Oil, and possibly a V8 ZJ Tie Rod swap and Tie Rod flip.
Title: Re: 1997 Jeep XJ Country
Post by: Spencer on April 03, 2012, 01:52:25 PM
those louvers look nice. that was a good buy
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 03, 2012, 01:58:27 PM
Thanks, I really like the look of them. Just need to paint them black, get the hardware to install them, and then of course cut the holes in the hood *cringe*. I'm more excited to take it out on a hot day and see if it really does help with the heat soak issue.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 05, 2012, 09:56:59 PM
Vents painted flat black (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash3/s720x720/560075_424451734237535_100000181353873_1846229_848346072_n.jpg)
One side cut (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash3/s720x720/523999_424452680904107_100000181353873_1846233_1909116172_n.jpg)
Test fitting (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/s720x720/427922_424453347570707_100000181353873_1846235_2090045720_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: s0l0ithz on April 06, 2012, 06:44:13 PM
Nice, hope it helps dissipate your heat issue
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 19, 2012, 06:00:24 PM
Good news and bad news. The good news is that my Cherokee is now locked in the back with an Aussie that I'm testing for Bill. The other good news is that I believe I found the ghost that has been robbing me of my gas mileage. The bad news is that I believe the exhaust manifold is cracked.
What do you all think? (https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash3/s720x720/578194_436614979687877_100000181353873_1883154_1525539880_n.jpg)
If that is what a crack like I think it is, does anyone have recommendations for a replacement? A lot of people on Jeep forum strongly recommend the APN manifold, just didn't know if anyone had any personal experience with replacements. The other thing I was gonna do is replace the motor and transmission mounts while I'm at it since this is also what a lot of people say causes the cracking. With mounts I literally am flying blind on knowing what to do. A lot of people recommend poly mounts, others say get OE rubber ones. So if anyone has suggestions/opinions, they would be greatly appreciated.
Link to APN headers. http://www.ineedparts.com/auto-parts/exhaust-parts/exhaust-manifolds/jeep-exhaust-manifold.html
Title: Re: 1997 Jeep XJ Country
Post by: s0l0ithz on April 19, 2012, 07:37:29 PM
could just weld the crack and call it done.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 19, 2012, 07:46:25 PM
My grandpa happened to stop by tonight and I showed him, and he suggested that too. Would the metal in that area be thick enough to really hold? I'd still end up doing the motor mounts to (hopefully) prevent it from breaking the weld anyway. But the strength and age of the metal would be my only concern, then again, I don't really know much about welding.
Title: Re: 1997 Jeep XJ Country
Post by: s0l0ithz on April 19, 2012, 08:42:05 PM
It will be fine
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on April 20, 2012, 06:09:57 AM
If it is the same as the TJ manifold, I have one in my garage that was cracked and repaired.
Title: 1997 Jeep XJ Country
Post by: etk300ex on April 20, 2012, 06:56:39 AM
I'd weld it. Worst case is it cracks again.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 20, 2012, 08:47:07 AM
Problem is I don't have a welder -_-
Any suggestions on motor/transmission mounts? I was looking at Brown Dog Rubber mounts because, again, that's what a lot of people on Jeep Forum recommend.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 26, 2012, 12:50:00 PM
So I ended up going with a set of headers rather than welding my old ones. The main reason is that since I don't have a welder, I didn't want to pay someone to do something that runs the risk of not holding. Also I since you have to pull the power steering pump and the intake manifold just to get to it, I didn't really want to risk having to do it more than once. The other reason, though not really that important, was the moderate mid range power bump that a lot of people report. Aside from all that, I didn't really think that $150 was that bad for a set of headers. For the motor/transmission mounts, I ended up just getting factory rubber ones from car quest due to budget reasons. Some day down the road I may upgrade to the Brown Dog ones, but for now, these should do fine. Hopefully I'll be getting to this all next week with some help from a friend and his dad. I'll also probobly finally be doing my V8 ZJ tie rod swap/flip then as well.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 29, 2012, 06:43:28 PM
Started taking things apart tonight, gives me a chance to clean the throttle body too. So far the only snag I've run into is trying to get the fuel line off of the fuel rail. Is there a trick to getting it off?
Sent from my DROID X2 using Tapatalk 2
Title: 1997 Jeep XJ Country
Post by: MrMindless on April 30, 2012, 07:05:21 AM
Push-lock type connector? There's definitely a trick. I dot know it though.
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on April 30, 2012, 01:45:18 PM
no need to, just flip it up out of the way... but it is a push lock.. you cna buy a tool that saves the hassle
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 30, 2012, 04:04:10 PM
no need to, just flip it up out of the way... but it is a push lock.. you cna buy a tool that saves the hassle
Found the tool in my dad's box that pops it off after I looked up what it looked like. I know I didn't need to completely take it out but I figured I may as well and would make things easier. I'm taking a lot of it apart separately to clean anyway (throttle body was nasty >.<).
Got everything apart today as far as the intake/exhaust manifold is concerned. Next order of business is to take out and replace the old motor and trans mission mounts.
if you’re putting headers on update the manifold to +99 and buy a bigger throttle body...
headers only work to their fullest if the engine can inhale as well as exhale better..
It's in the plan. I'm going to eventually get mine bored to 60 mm as well as instal a spectre cowl intake. Right now money is the only thing holding me back.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 07, 2012, 10:15:05 AM
New header has been in for a couple days and has been WP tested. Cant say anything on my gas mileage until I get a few tanks of fuel through it. I can say that I do feel like I make a bit more power 1500 RPM and up. I don't feel like I have to give it as much gas to maintain highway speeds. Hopefully it's not just me, but so far, I give the APN header a thumbs up.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 29, 2012, 03:39:36 PM
Few small updates. MPG so far has increased from 11.5 mpg to 15 mpg after 4 tanks of fuel, as long as that keeps up, I'll take it as a victory. 4x4101 claimed my connector for the fuel pump, big thanks again to Mike M and Matt for fixing it for me. Couple minor mods have been done as well.
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash3/s720x720/537672_469205016428873_100000181353873_1984894_1844696526_n.jpg) V8 ZJ tie rod swap
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash3/s720x720/550391_469204276428947_2069087930_n.jpg) Don't know why I said this is minor, obviously the most important modification anyone could do. The LOUDEST shock boots known to man.
Next on the list is a gas tank skid and possibly a Pinion seal on my rear dif. Then it's just saving the money for a trip to Rausch, hoping to go either late July or August.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on May 29, 2012, 03:44:27 PM
SWEET boots!
Title: 1997 Jeep XJ Country
Post by: MrMindless on May 30, 2012, 06:40:49 AM
That pic doesn't do justice!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 13, 2012, 08:35:00 PM
Considering that. Harrison and Spencer suggest going 3 link. The thing that's selling me so far on the TnT kit is the belly pan and the number of positive reviews it has. Still researching and considering options.
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on September 10, 2012, 12:41:24 PM
I like 3 links because using a radius arm or 4 link setup that inherrently binds and needs rubber bushings in order to work so it can deform them just seems dumb to me. That being said, I've wheeled with tons of XJ/TJs with bolt on radius arm kits that work well.
Radius arm would probably be fine if you don't wheel a ton. I've got a couple Ruff Stuff heims that were new in January and are spanked now but I'm guessing they have over 20 days of hard wheeling on them this season. I can't imagine how a stock UCA rubber bushing would hold up if I had radius arms and wheeled them this much. I've watched people with stock rubber UCA bushings spinning their wheels on obstacles and the axle jiggles all over the place.
I wore out stock bushings in like two runs and bent short arms, so I rebuilt them stronger and used flex joints instead of bushings. Then there was nothing to deform so my UCA mount broke instead. Went to 3 link and have been problem free since.
Title: 1997 Jeep XJ Country
Post by: MrMindless on September 10, 2012, 02:16:59 PM
Well put, Harry.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 11, 2012, 12:15:42 PM
I've decided to go with the TnT kit. The main reason being is that it's within my budget, or at least what I planned on this being. I liked the idea of running a 3 link but I'm not planing on staying at 4" of lift forever. With the Radius arms, I can see it being easier to adapt to a different lift height than a 3 link. There were also some things that I was reading where people have retro fitted the TnT belly pan to a 3 link set up, so I have that option available if I feel like going to a 3 link later. TnT's long arms still have a great reputation for it's flexibility and how strong the belly pan is. Another thing I like about the TnT kit is that it's something I can instal myself, not that I don't like having smike build stuff for me and working on my XJ, I just like being able to do what I can to it to understand it better and make it more of my own. That all being said, I should hopefully be ordering the kit tomorrow.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on September 11, 2012, 01:15:08 PM
Another thing I like about the TnT kit is that it's something I can instal myself, not that I don't like having smike build stuff for me and working on my XJ, I just like being able to do what I can to it to understand it better and make it more of my own.
Nothing wrong with that. If it breaks, you'll be better equipped to fix it. sMike won't always be with you.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 21, 2012, 09:15:45 PM
All prep work done. Was supposed to have the frame stiffeners in today but 2 friends that were supposed to bring over their welder bailed on me. One of them is supposed to show up first thing tomorrow morning to get these on. If that happens, with any luck, I should be able to get the rest of the long arms done. On a side note, this belly pan is friggan beefy. Damn thing weight 57 lbs alone, 1/4" steel everywhere on it. The control arms them selves are heavier duty than I thought as well. I don't see this bending anywhere near as easily as my Rusty's T-case skid did from one weekend of Rausch.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on September 22, 2012, 06:15:13 AM
Git-r-dun so you can field-test it next weekend at RC!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 22, 2012, 02:13:18 PM
If I could have one thing go smoothly with this, it would be a miracle. Fitment issues with the belly pan, welding that my friend did could probably have been done better by a crippled guy having a seizure. Have to call T&T Monday and figure out what to do about the fitment issues. May just throw the stock cross member on and ask Mike to do the driver's side stiffener and get the passenger side in better.
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on September 24, 2012, 02:58:44 PM
If I were around, I'd have welded them on for nothing as long as you kept me topped off with greasy food and beer! ;D
How's it going though? Any chance of making it to Rausch this weekend?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 24, 2012, 03:17:06 PM
No Rausch this weekend. Taking this pile to Smike Monday or sooner to fix the passenger side stiffener and instal the driver's side one. Also need him to put a new weld nut in where the stud for the T-Case cross member attaches to frame. Tried extracting one myself letting it sit in PB and heating it, just ended up breaking the weld nut. T&T is sending me a new skid (the smaller piece that attaches to the back of the main belly pan), guy said that there was a batch that was made wrong. I can still instal the rest of the belly pan, just not the smaller skid plate on the back.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 03, 2012, 01:46:10 PM
Jeep came home Monday after Smike did an awesome job fixing/installing the frame stiffeners. Haven't done anything other than put it up on the lift and look at it. Between waiting for replacement parts from T&T and lacking ambition to work on it. I'm gonna take a swing at it tomorrow, goal is to finish getting the belly pan mounted and maybe get to hacking off control arm mounts.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 04, 2012, 09:24:00 PM
All support brackets for the belly pan mounted. Never thought drilling 6 holes would take all day, but between the positioning, drilling, having to run to the hardware store to get stuff. Pretty much all there is left to do is mount the long arms, cut brackets, and get it all aligned. (https://sphotos-a.xx.fbcdn.net/hphotos-snc7/3443_537655686250472_974056000_n.jpg) (https://sphotos-a.xx.fbcdn.net/hphotos-ash3/66354_537655766250464_983836165_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 08, 2012, 03:50:32 PM
Been slacking off for a few days and got back into it today. Both LCA brackets cut off. They aren't pretty, I'm a little nervous with the grinder and getting that close to the frame rails. I'll probably just leave them for now since they clear and figure out what to do about them later. Aligning this thing should be easy. It's already pushed the axle forward a touch with the 1 long arm in and as short as I can make it on the passenger side and the short arms still on the driver's side. Might push it forward a hair more once I have the tires on it and see how it sits before I get everything tightened down.
Finished at about 11 tonight, disconnected the sway bar and took it for a quick test run up a ditch that has a few somewhat challenging rock climbs. I can definitely feel a difference in how the front end acts. I'm guessing that it's a combination of the long arms and the frame stiffeners/belly pan keeping the vehicle itself rigid. Overall, VERY happy with it so far. Also, Spencer, normally the brake line is loose, with no tension on it. I just had it zip tied to get it out of the way.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on October 09, 2012, 09:00:01 AM
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 16, 2012, 04:26:20 PM
Got a couple small updates since the last time.
Replaced the broken grille with a maroon one which I sprayed flat black. (https://sphotos-b.xx.fbcdn.net/hphotos-ash4/301253_569434916405882_1236108889_n.jpg)
Painted the amber part of my tail lights with a transparent red model paint. (https://sphotos-a.xx.fbcdn.net/hphotos-snc7/375447_571846519498055_16889897_n.jpg)
And scored a set of crap brand 50-60% tread 35x12.5s (https://sphotos-b.xx.fbcdn.net/hphotos-ash3/556350_573096986039675_350696967_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: jACeL86 on December 16, 2012, 07:12:51 PM
Wild country's aren't horrible as far as imports go. It's one of cooper tires offshoot private labels. (Multi mile)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 16, 2012, 07:21:18 PM
Yeah, since I got them on I've been browsing forums and people say they aren't terrible. I'm gonna end up taking them off and putting my 31s back on anyway. The 35s are on rims with 5.5" of backspacing and they rub on my leaf springs. So I need to find a set of wheel spacers before I use them. A friend of mine says he's gonna be selling his 35" BFGs in the spring, so I might buy those from him and use these as spares. Wheeling is going to be minimal this winter so that I can fix a few other things on it and get it all set up for next spring, so I have plenty of time to get tires sorted out.
Title: 1997 Jeep XJ Country
Post by: Spencer on December 16, 2012, 09:47:33 PM
I'll be selling my 33" swampers in the spring if you're still interested in considering those
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 16, 2013, 07:06:50 AM
So I haven't really had much to update in a good while, haven't really had the finances to do anything. Had to sell the 35s I got due to getting fucked over financially, I atleast got what I paid for them. So upgrades have been low on the priority list. With the nice weather we've had over the past couple days, I did something I've been wanting to do for a while now. (https://sphotos-a.xx.fbcdn.net/hphotos-prn1/46606_640652269284146_990609483_n.jpg) (https://sphotos-b.xx.fbcdn.net/hphotos-prn1/541906_641607922521914_1752914923_n.jpg)
Doors are fully removable and able to put back on. I haven't decided if I'm going to do the rear doors yet or not. So far the only issue I've had was that the bronze/brass w/e bushing inside the hinge was toast and I haven't been able to find a source for replacements. This causes the door to sag a bit when its open, but when closed it fits like factory. I've got a couple ways I've been thinking I could solve this. 1: Just leave it and deal with having to lift the door up a bit to close it. 2: Continue searching for replacement bushings. Or 3: Drill out the hole for the hinges to 5/16 and get an oil impregnated bushing from McMaster Carr with a 5/16 OD 1/4 ID. I'm kinda leaning towards #3 but because of how close the hinges are to the body, I could see drilling it out being troublesome. On another good note, I've got a good lead on a Job I'd really like and if I get that, first thing on my list is going to be tires. I'm sick of dealing with tiny 31s (30s by this point :/ )
Title: 1997 Jeep XJ Country
Post by: MrMindless on April 16, 2013, 10:10:20 AM
Drilling out the holes for good pins and bushings is definitely the way to go.
Title: Re: Re: 1997 Jeep XJ Country
Post by: Callelle on April 16, 2013, 12:14:40 PM
Drilling out the holes for good pins and bushings is definitely the way to go.
That's what I'm leaning heavily towards. After 2 days of looking, I can't find OE bushings without having to drop $40 a new hinge. The concern is just how close to the body it is. I'm not even sure my 90 degree drill will be able to get close enough without the hole being cock eyed. Edit: Good news, 90 degree drill can get at it as long as I drill the top one out from underneath. Sent from my SCH-I535 using Tapatalk 2
Title: Re: 1997 Jeep XJ Country
Post by: fasteddie on April 16, 2013, 08:35:22 PM
those bushings are available through dorman p/n 38439 pin 2 bushings sleeve & clip for like 7.50 .
Title: Re: Re: 1997 Jeep XJ Country
Post by: Callelle on April 16, 2013, 10:26:15 PM
those bushings are available through dorman p/n 38439 pin 2 bushings sleeve & clip for like 7.50 .
Those are for the newer style hinges.
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Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on April 17, 2013, 08:50:15 AM
I had that same issue with Dorman HELP! stuff for my Ram - the diameters were all wrong and I'd have had to completely dismantle the hinges and drill out both sides. Wasn't worth it, I stuck another washer in the bottom hinge.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 17, 2013, 11:16:25 AM
So finishing some of the work on the passenger side has raised an interesting question. The brass bushings weren't in as bad of shape as the drivers side, so I greased the pins and hinges up and tried getting the door in. No dice. It seemed no matter how much I fiddled with the positioning of the hinge door side, I could never get it to line up to drop in. All I ended up doing was sliding the pins on top of the hinge and destroying what was left of the bushing. If I drill out the hole and get the replacement mcmaster carr bushings, will I just end up doing the same and destroying those? Or do I have to / should I take it to a shop that's had experience lining up doors on new hinges once I get the new bushings?
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on April 17, 2013, 11:21:32 AM
with bigger bushings and pins with more of a taper you may have better luck?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 15, 2013, 10:33:43 AM
Got the bushings from McMaster Carr a few weeks ago, finally got the motivation to finish aligning the pins last night because I needed to drive it and it was supposed to rain today. Every thing lined up and slides in and out easily, still have a little tweaking on the drivers side but it definitely doesn't sag when you open it any more. I love that I did all the work just because it was supposed to rain today and now its gorgeous out.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 13, 2013, 09:23:48 AM
Did a fun small little project recently. Seats were collapsing and just getting over all beat so I decided to replace them. Did some researching and found that WJ seats will bolt right up to the XJ brackets. So I hit up M&M and scored some surprisingly good condition black leather seats out of an 04 with 10 way power for $50. The WJ I pulled them from was victim of a pretty bad driver's side impact so I wanted to double check everything, especially since it was leaning pretty bad to one side. Sure enough the seat frame was broken in two and the back was broken at one of the cross supports. Simple enough to fix, so I welded them up and got them all back together on the XJ brackets got finished installing them yesterday afternoon.
I even got the power recline and lumbar to work. The seats are a lot more comfortable and more supportive than my old beat cloth seats. Only downside is they sit a bit higher so I'm even more cramped than I was before, though it's just like riding in any other car. Hopefully I'm going to be able to address this by pulling them out again and cutting down the brackets so they sit at least 1/2" lower, until then, I'll just have to deal with the ghetto lean.
Other than that I've also replaced my worn out (disintegrated) upper shock bushings with poly ones, and am going to be addressing my rear hatch's reluctance to open when I want it to today. I'm also looking for some suggestions on tires. Now that I've recently gotten a job driving and only burned one bus to the ground so far (https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1082281_693205027362203_1188683311_o.jpg) (yes, that's what happened on my second day), I've been putting some money aside and hopefully I'll be able to have new treads within a month or so. I had my mind pretty much set on Goodyear MT/Rs with Kevlar, but after hearing a bit from smike and then doing a bit of research about them being hard to balance has me back on the fence. I don't really like mud a whole lot so slop performance doesn't really matter to me. My main concerns are going to be for crawling but I do drive my XJ daily as my main vehicle, so tread wear would be nice to keep in mind too. I'm planning on 35x12.5R15s. Any suggestions/opinions would be appreciated.
Title: Re: 1997 Jeep XJ Country
Post by: gCracker on August 13, 2013, 03:26:52 PM
holy cow.. what caused the fire?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 13, 2013, 05:19:26 PM
Long story short; blew a tire on the thru way, looked like a recap blew off of one of the duals, boss told me to nurse it to the nearest terminal. Half way there I look out my mirror and it's just billowing black smoke, pull over get out and "holy fuck I'm on fire!"
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Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 16, 2013, 08:43:30 AM
Fenders re-trimmed and ready for 35s. (still need to cut back my rocker but I'll be doing that soon) (https://scontent-b-lga.xx.fbcdn.net/hphotos-ash3/q82/s720x720/1236420_723241801025192_625354854_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 23, 2013, 08:20:16 AM
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on September 23, 2013, 10:04:22 AM
fingers crossed for no balancing woes!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 23, 2013, 10:40:07 AM
^ That. Gonna be trying that Equal balancing compound stuff, a few of my friends have had good luck with it. I still need to get my rockers cut and old tires demounted so I can clean up and repaint the rims.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 04, 2013, 05:40:43 PM
Drove up and down the road to 60 on the speedo and no wobble or vibes
Title: Re: 1997 Jeep XJ Country
Post by: etk300ex on October 07, 2013, 10:12:12 AM
Looks more better!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 07, 2013, 11:01:24 AM
Thanks, I still got a few things to do before it's where I really want it. Ordered 8" lift shocks for the front, need another 1" of bumpstop in the rear, and shackle relocation boxes are happening this winter. For the rear bumps, I already have a 3" bumpstop sitting on top of a 2x2 square tube. I'm thinking for Rausch, I'm just gonna stack washers to get me by for one trip or until I figure something else out. I don't know if I really want to spend $100 on bumpstop plates to sit over the leafs just yet. Shackle relocation boxes are also going to have to wait until this winter just because I don't think I have enough time to instal them before next weekend. As far as the tires go, the only issue im having is a small amount of rub on the inner fender at full left lock while in reverse. I think it's just because of a combination of my size, soft springs, and no sway bar causing it to lean a little on the driver's side. I've tried pounding it in but it wont budge. I don't think it's something I need to be overly concerned with because I've hammered the pinch seam down flat and there's nothing sharp for the tire to get cut on. Whole bunch of extra things I just have to think about this winter and where I want the XJ to sit. I've been debating on getting some 3.5" leafs for the back and a little extra ride height and up travel, but for the low CoG set up I'm going for, my semi flat leafs in the back will be better for droop, especially once my shackle angle is corrected.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 15, 2013, 12:27:14 PM
(http://img.tapatalk.com/d/13/10/16/yrydygy8.jpg) Bumpstop plates installed. Just need to get the new front shocks in and I'm as set as I can be for Rausch.
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Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on October 15, 2013, 03:52:57 PM
still locked in front? got your spare shafts!?! :)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 15, 2013, 09:33:07 PM
Still locked and have spare shafts. Was working on getting shocks installed tonight and I fucked up somewhere in my measuring. They're about an inch and a half to long. I'm sure in the end it doesn't really matter, but I'm debating in my head which shocks to run. The ones that I had would net me the extra 1.5" of up travel where as the new ones would get me 2-3" of down travel. I know that I'm building my XJ based on droop and the only reason I'm considering keeping the old shocks is because of my already small amount of up travel. Like I said, I'm sure that it doesn't really matter which one I stick with and that I'm just debating 2 moot points within my head. I'll more than likely end up going with the longer shocks and add another 2" of bump stop in the front and just see how it does. Hell I may even just my old ones to Rausch and swap them if I don't like how it's acting. Any thoughts?
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on October 16, 2013, 09:04:28 AM
Severely limited uptravel is really uncomfortable. If you're stiffly sprung, I'd not go less than 3" of up. If softly sprung that's too little.
my 2¢
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on October 16, 2013, 11:11:14 AM
35s look good! Remember to STOP when you hear the front shafts pop ;D
I probably have 2" of up in the front on my whooped coils. I can feel them bottom out sometimes. I still have 1" up in the rear (with really soft bumpstops, so probably 1.5-1.75" in reality) because my driveshaft is too long. I would have done something about either end if it bothered me.
This is all 99% trail time. It seemed fine in the 10 miles it's been driven on the road like this, but that is obviously not very extensive testing.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 16, 2013, 12:10:33 PM
(http://img.tapatalk.com/d/13/10/17/e4ehyty9.jpg) Flex test, this is with the new shock bottomed out. I'm gonna add another half inch of bump in the back and another inch up front. I also need to bend the hard line for the brakes a bit lower.
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Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 17, 2013, 01:24:10 PM
Everything set for this weekend. Only thing I didn't get done was moving the hard line on the front brakes. Soft lines are at their limit just before the shock is bottomed out. I think my back is going to lift before I max out the front though so I'm hoping I'll be fine this weekend. My only other concern is rubbing when the front is compressed and turning. So far it's only done it at full lock going backwards. Here's hoping I don't have any major issues.
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Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 22, 2013, 08:08:04 AM
The XJ survived the trip this weekend, didn't break anything. Couple of things need to be reworked. Front bump stops completely failed and fell apart due to poor assembly and rushed hack job. Need the front brake lines lowered which will probably mean new hard lines. New BDS 3" leafs are going to happen as well as shackle relocation boxes and forward spring hangers. Front driver's side shock mount on the axle needs to be bent back down and gonna probably do a limiting strap of some sort. All in all I was really impressed with what I could do. The 35 MTRs are amazing, Rock Creek is now one of my favorite trails. Girlfriend had a great time and now she wants to start looking for a rig of her own. Although I didn't get to do much with it, I'm thinking the Cherokee is going to be put up for the winter, I don't really want to put it in salt and save what I can of it. Winter projects, other than what's listed above, are going to include New trac bar, finish plating the frame, replace driver's floor pan, rear bumper with tire carrier, possibly an exo cage, dropping everything other than engine/trans for cleaning/paint, POR15 under body.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on October 22, 2013, 08:54:54 AM
This really worked. Everything attempted was conquered. Nice job!
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on October 22, 2013, 02:35:02 PM
Nice!! Glad everything worked all weekend without issue.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 19, 2013, 07:13:22 PM
Got the next 2 weeks off for Christmas, gonna tear into this thing and at least get started on some things I've been wanting to get done.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 20, 2013, 02:28:08 PM
(http://img.tapatalk.com/d/13/12/21/y3e6a6eh.jpg) Picked up a Lund sun visor for $35. Gonna do some test fitting and minor repairs in chips before I commit and drill it in.
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Title: Re: 1997 Jeep XJ Country
Post by: gCracker on December 20, 2013, 03:03:52 PM
Wait till that catches on a tree branch...
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 20, 2013, 07:14:26 PM
The way the bottom angles, I think it could be less of an issue than you think. Not saying it will prevent it from happening, I just think it might deflect them around it.
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Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on December 22, 2013, 02:55:02 PM
You'd REALLY want to run some brush guide lines from the front fender corners to the outside I the visor to keep branches from catching. Otherwise if give it two trips before noticeable stead cracks and a season before failure.
Tapatalk (http://tapatalk.com/m?id=1)ing in traffic
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on December 22, 2013, 03:28:02 PM
Exo-cage over it!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 26, 2013, 02:46:02 PM
Disassembly has been slow but progressing on this. Got the rear bumper, hitch receiver, gas tank skid, and some of the steering removed. Taking a gas tank skid off is not a one man job when it's 5 feet in the air. Hoping to get the axles off this weekend so I can start on them. Scored some brand new JKS quicker discos for $100, need to put some new axle side mounts in that are about 2" taller so that the passenger side end of the tie rod doesn't contact it from the axle being pushed forward a bit. By the end of next week, I'd like to have everything taken off that I need to so I can start cutting and getting into more trouble than I bargained for.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 28, 2013, 06:52:34 PM
Got the front axle out. Would have continued on to the rear but I don't really understand how the e-brake cables separate. There's a little box that attaches to the frame where it combines the one cable from the lever inside to two that go to each axle, I kinda guess that's where it all separates but I don't know how to do it. Once I get the rear axle off, I'm gonna start cutting the shackle buckets so I can order/put in the shackle relocation boxes. After that I want to put in new forward spring hangers and finish plating the frame and put in a new driver's floor pan.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 04, 2014, 04:17:47 PM
Small update: Rear axle about ready to come out. Parking brakes are basically going to need new cables all around so I just ended up cutting them. Adjuster on the "splitter box" for the e brake is going to need to be rebuilt also. Started cleaning up some of the metal and other things in PB. Would have liked to have everything pulled by now and reading for more frame stiffeners and rear suspension work, but oh well. Picking up a spot weld cutter tomorrow so that I can start getting ready for new spring hangers and driver's floor pan. I still got 2-3 months before I'd like to have it back on the road so I don't feel any need to rush.., yet.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 11, 2014, 05:44:08 PM
Got the rear axle off today as well as the rear seat and carpet removed. Also started removing some of the forward spring hangers. Time to start ordering parts ;D
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on January 14, 2014, 04:21:43 PM
those spot weld cutters suck. i did chips XJ's forward mounts. it was a pain.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 14, 2014, 09:25:09 PM
I cleaned off some of the forward mounts and only some of the spot weld marks are still there. For the ones that I can still see I'm gonna try the cutter on them, the rest I'm going to have to just whittle away at with a grinder. I think the forward mounts are welded on the sides too by the look of it. They're definitely welded where the frame stiffeners are.
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Title: Re: 1997 Jeep XJ Country
Post by: Callelle on January 15, 2014, 12:04:49 PM
Just discovered I'm going to have to cut 3 3/4" of the frame stiffeners off in order for the spring hangers to fit. -_-
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Title: Re: 1997 Jeep XJ Country
Post by: Callelle on February 01, 2014, 06:59:00 AM
Been building up a stock pile of parts. Have new spring hangers, shackle relocation brackets, and rear frame stiffeners sitting in my closet. Last night I also ordered my rear bumper and tire carrier kit. Was planing on getting the rest of my rear suspension stuff but the bumper was $60 off and I figured, what the hell, I'm going to be ordering it anyway right? Anyway, I'm hoping to get the spring hangers and rear frame stiffeners installed tomorrow, gonna depend on how much of a pain in the ass it's going to be to get the old hangers off and trim back the stiffeners that have already been welded on.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on February 02, 2014, 07:57:19 PM
Got one side burned in with the aid of Josh Wolck. Smike was right when he said the old ones were a bitch to remove, even more so when you have frame stiffeners welded to them. Gonna whittle away at the driver's side until Josh can be back over with a welder (I really need to get one for myself) and do as little damage to the frame rail as possible. Good thing these things are beef and will be tied into frame stiffeners in front of and behind them.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on February 18, 2014, 09:51:39 PM
Driver's side hanger installed and burned in (https://scontent-a-lga.xx.fbcdn.net/hphotos-prn1/t1/p180x540/1012065_820400704642634_1781887400_n.jpg)
And driver's side rear frame stiffener burned in (https://scontent-b-lga.xx.fbcdn.net/hphotos-prn2/t1/p180x540/988392_820400884642616_1098455178_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 12, 2014, 09:23:28 AM
More parts ariving. IRO double shear track bar and 3.5" leaf packs. (https://scontent-a-lga.xx.fbcdn.net/hphotos-ash3/t1.0-9/10013795_832926630056708_734034079_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 20, 2014, 04:01:28 PM
Was never really sure what I wanted for coils to match the rear, but I found brand new Rubicon Express 4.5" spring on Amazon for $76 bucks. So I went with the "well it's less than $80 so I may as well" logic and got them today. Now that it should be warming up soon, I'm gonna start getting the axles and underbody cleaned up and ready for painting. I've also decided to go with the Currie Correctlync setup for my steering. I like that it uses tie rod ends rather than heims so that it won't loosen up from contamination since it's a daily driver.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 22, 2014, 03:30:37 PM
Pulled the rest of the carpets today. I knew the driver's pan was going to be replaced, but it was worse than I thought it was. Rather than just two holes, its soft and crunchy all the way around. Either way, that pan is getting completely replaced. Passenger side is actually a lot better than I thought it would be. Just a couple soft spots that I'm just gonna cut and patch. After all that is finished, floor is going to be bedl ined. (https://scontent-a.xx.fbcdn.net/hphotos-frc3/t31.0-8/p180x540/1900361_839507212731983_609316096_o.jpg) (https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/t31.0-8/p180x540/1891333_839507356065302_1723181429_o.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 30, 2014, 04:55:04 PM
Well the plan was to get the passenger side stiffener finished today. Got everything cleaned up and prepped, go to weld, and my friend's welder took a shit. Wouldn't keep a solid arc going, even on new steel, so no penetration was going on, just surface globs. This everything just seems to be fighting me to get this passenger stiffener on. On the other hand, I got all the stuff for replacing/repairing the floor. Gonna start on that hopefully this week when it warms up a bit. Starting to get real fed up with winter, I just wanna get this thing finished and wheel.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on March 30, 2014, 05:12:27 PM
Keep at it. A little progress is still progress.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 30, 2014, 09:05:12 PM
Yeah, slowly but surely. I got a couple things I can do without the welder. Prepping the floor for the new pan instal, tacking some of the bumper stuff together with my sick (I don't trust myself enough with it to work on the frame), and maybe some cleaning for paint prep once it warms up a bit. On a positive note, the girlfriend got me an awesome early birthday present which should be arriving either tomorrow or Tuesday. Maybe that will be the moral boost and motivation I need.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 01, 2014, 03:49:37 PM
(http://img.tapatalk.com/d/14/04/02/y7y2u3ag.jpg) I have the best girlfriend ever.
Sent from my SCH-I535 using Tapatalk
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 05, 2014, 10:23:57 PM
So a friend is actually letting me borrow his welder for a while since he's had now use for it. It's just a little 110 Mac Tools mig, but its got a full tank of gas and a fresh spool of wire. Can't wait to see what kind of bastardization of a bead I can lay down after not welding since I was about 14. Either way, it's practice and I can actually try and make some real progress on my own for once.
Title: Re: 1997 Jeep XJ Country
Post by: rejeep on April 07, 2014, 12:57:36 PM
didnt buy it from me... she cant be that good. :'(
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 07, 2014, 01:49:39 PM
Actually when she was asking about what I wanted to buy one for me, I told her to let me know so I could have her contact you. I guess she got it through 4wheeldrivehardware on their Ebay store because she could use "Bill me later" and get no interest for 6 months or something like that.
Sent from my SCH-I535 using Tapatalk
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 13, 2014, 07:54:24 PM
Made a lot of progress today. Passenger rear frame stiffener welded in. (https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/p180x540/1545729_852289718120399_1291922585274723123_n.jpg)
Got about 1/3 of the floor cut out. (https://scontent-b.xx.fbcdn.net/hphotos-frc3/t1.0-9/p180x540/1233399_852289818120389_1442656723260469306_n.jpg)
And got the main section of the rear bumper tacked together. (https://scontent-b.xx.fbcdn.net/hphotos-prn2/t1.0-9/p180x540/1507952_852289791453725_7327602106407621445_n.jpg)
Not shown, I also got the shackle relocation brackets for the most part mocked in and ready for final installation after everything gets washed and painted. Went through my first whole bottle of gas and wire spool for the welder, though 99% of it was from a friend that's teaching me to weld as I go. I'm gonna ask the friend who's letting me borrow it if I could buy it off him since he's already told me he doesn't really use it to begin with. It's just a little 110v Mac but it's working fine for what I'm doing with it and would probably be good for anything I'd need a welder for in the future.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 17, 2014, 05:33:29 PM
Got the shack relocation mounts finished and installed, also got the rest of the floor pan cut out but I still have some work to do getting it fitted in right.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on April 26, 2014, 02:32:18 PM
Got the floor pan in. I have a few small patch plates to cut and put in from where I cut too much out, but the main bit of it is done. (https://scontent-b.xx.fbcdn.net/hphotos-prn1/t1.0-9/p180x540/10261959_860670170615687_1171040562619956901_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 19, 2014, 09:16:33 AM
Slowly making progress on this. Got the rear shock mounts cut off can cleaned up to get the new ones ready to weld on. Two holes behind the front floor pan patched. Mostly getting stuff cleaned up and painted, bench is coated in powder coat dust from wire wheeling it off of my long arms and I'm gonna be sand blasting the spots on the front axle where I cant get to it with the wire wheel. Also de-scaled both axles. Got my motor mounts on Wednesday and my Currie steering should be here tomorrow. Got a friend that bought a new set of 4.56 gears and D30 carrier for his XJ but sold it for a JK and he's selling the gears to me for $300, can't pass that up and I hope to pick those up Wednesday this week. A friend of mine is going to be coming over this weekend and we're hoping to get the new motor mounts in and the front axle on so that it can be sitting on all for tires on it's own. Once that happens, all I "should" have to do is get the rear axle shimmed and new drive shafts and brake lines to make it drivable. Probably going to ask Smike to put my rear bumper together since I'd rather make sure it's done right for something that's going to take abuse like that. Slowly but surely it's coming along.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 19, 2014, 09:08:26 PM
Gears, master instal kits, and D30 carrier acquired. One thing I don't get is why the box for the 8.25 gears says "Noisy" on it.
Title: Re: 1997 Jeep XJ Country
Post by: jaysenodell on May 20, 2014, 05:47:14 AM
Maybe they make a lot of noise? :)
Sound like you're almost there.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 25, 2014, 08:16:27 PM
Good news, it's sitting on all 4 tires again! Still have to set control arm and track bar lengths properly but I just wanted to get it to the point that they're in and I can figure out where I'm gonna need everything to sit. Also got my new motor mounts in and found a drive shaft for the front.
Bad news, 2nd drive shaft I found isn't long enough for the rear and is maxed out at ride height, so I'll be getting a new tom woods one for that. It's sitting a lot taller than I wanted it too, granted there's no weight with the interior gutted, bumper not done, and winch not installed yet. Really hoping it settles down at least 1-2 inches once it gets weight in it.
Either way, I'm happy that it's sitting on it's own again with the lift arms to the side. Next steps are going to be ordering a few minor parts, getting the rear buttoned up, front linkages all set to right lengths and new hard lines for brakes. (https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/q74/s720x720/10365861_880374681978569_1495474106489954621_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 08, 2014, 01:54:38 PM
Got a number of things accomplished this weekend. Leaf spring shims in, control arms are set, new hard brake lines all around, steering in, and winch installed. (https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/q71/s720x720/10444547_889601171055920_5671434223226069710_n.jpg) (https://scontent-b.xx.fbcdn.net/hphotos-xpa1/t1.0-9/q74/s720x720/1560625_889601264389244_1392515601666323497_n.jpg)
Things left to do: Rear axle shock mounts Instal drive shafts (possibly order new one for rear) Order rear shocks Fix driver's seat mount and frame Clean and bedline interior Alignment Bleed brakes Have rear bumper built Reinstall interior Tighten/double check every bolt I've touched in the past 8 months
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 21, 2014, 07:17:45 PM
(http://img.tapatalk.com/d/14/06/22/ezymyvaq.jpg)
(http://img.tapatalk.com/d/14/06/22/6yma7a4u.jpg)
First time outside in 8 months.
Sent from my SCH-I535 using Tapatalk
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on June 21, 2014, 07:31:40 PM
Yea!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 22, 2014, 03:08:17 PM
Off to smike's for rear bumper build and shock mount instal.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 29, 2014, 09:28:51 AM
Bumper done, shock mounts welded on, and rest of floor patched thanks to Smike. Will post pictures when stuff is all painted and nice.
Current to-do list Buy and instal rear shocks Rear drive shaft Bedline interior Re-assemble interior Register, inspect, align, etc...
So close to done, I just can't wait to drive and wheel it. Anxious to see what it can do.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 06, 2014, 05:46:06 PM
Bumper done and installed. (https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/p180x540/10481615_908817505800953_6872008943447807078_n.jpg)
Got 3 coats of chassis saver on the floors and should be laying down the monstaliner tomorrow, interior shit the day the day after. Then all that I'll have left is the shocks and bump stops, inspection and all that other bull shit.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 10, 2014, 05:32:56 PM
Got this thing out to run up and down the road yesterday. I've never had death wobble and I always see people complain about it, but I got up to 70 with no stabilizer and it not even being close to aligned and it didn't even make a shudder. Had some issues with the floor getting hot and a few bubbles in the bedline popped up, ordered some exhaust wrap to wrap around the muffler and some adhesive heat barrier stuff to hopefully deal with that. Also ordered my rear shocks (Bilstein 5100s), rear BPEs, a cover for the winch, and a license plate bracket for the tire carrier. These "should" be the last few things I need to order, but stupid stuff always pops up.
(http://img.tapatalk.com/d/14/07/11/5unuvyta.jpg)
Here's a quick little picture at how it flexes out from when I was checking bump stops and measuring for shock lengths. I'm really happy with how it is, and can't wait to get it out and on some trails. Current plan is a 4 day weekend at Rausch in August as a little birthday present to myself. There is one thing I'm sort of concerned about, at full compression and on the bump stops, the leaf is ever so slightly going into a negative arch, but only in front of the wheel, behind the left spring perch, it's not even flat and still has arch in it. I thought about moving the shackle back one more spot, but when I rock the Jeep a bit, the shackle still has room to move back. I've never really seen or read anything like that, is that just how a leaf set up is and is nothing to worry about or is it something that I should be concerned with?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 13, 2014, 08:53:40 PM
Hit the muffler with heat wrap and got some adhesive heat barrier stuff on this thing today, haven't driven it around yet to see if it works but fingers crossed. If I'm honest though, I'm not sure how long the wrap is going to last being exposed on the underside. While I do have additional belly height from the 35s and extra lift, I just feel it's going to be wasted money. If it gets me through this year though, I suppose I can say it's worth it. Perhaps next winter, I'll pull the transfer case and do a better job of putting some heat shielding up and replace the beat up exhaust in the process. Getting it licensed tomorrow, aligned Wednesday, and inspected, hopefully, Thursday or Friday.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 18, 2014, 12:30:11 PM
Right when I thought this heep was all ready to go, got inspected, insured and registered all smooth, then the radiator starts leaking. New CSF 2 row all aluminum radiator ordered.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 25, 2014, 08:41:45 PM
Glad that I decided to replace my radiator now than wait and hope for the best after Rausch in August, drove into town and it was puking coolant rather than dripping by the time I got back. Either way, new radiator came today and I'm pretty impressed with the quality of it. Gonna tear into it tomorrow.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 28, 2014, 08:11:55 AM
Radiator installed, transmission flushed, trans cooler relocated, oil changed, oil pressure sender broke. Haven't taken it out yet because I need to get some more trans fluid in it, gonna drive it out to Rochester Wednesday for the club meeting. I did have it idling in my shop and it was sitting just a hair above 210 on the gauge, or at least how it used to be. Hopefully this solves my cooling issues, if not, the only things I can really think of to replace would be the fan clutch and the water pump.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 03, 2014, 09:10:28 PM
Ugh, I feel like I'm chasing ghosts on my temp issues. Took it out today to a semi-local wheeling spot and over heated twice, both of them going up long hills. I know I need to replace the e-fan because at some points it was spinning fine at full speed, others it would barely be moving, you could stop with your finger and then it wouldn't even try to start unless you spun it by hand to kinda of jump start it (pulled the plug for the thermostat to force it on). The other weird thing I noticed is that when my gauge on the dash was reading 260 and the "check gauges" light was on, I got out, opened the hood and nothing was boiling over in the over flow bottle. Honestly it doesn't look like the fluid level has changed at all in the bottle since I filled it. My Jeep only has 93k on it and I'm not getting any leaks or noises from the pump so I'm not really seeing how that could be bad. Anyone have any ideas/suggestions?
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on August 03, 2014, 10:51:16 PM
What # rad cap do you have on it? I run a 24-26 on the buggy, so it will barely be boiling by 250-260... Much depends on water flow vs sensor location too. I'd expect some water to have gone to overflow at that temp though.
Is the system fully bled of air?
Replace the fan and go from there, it's a problem that exists. Might be enough to take care of it. Or course, XJs aren't known for good cooling....
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 04, 2014, 06:38:55 AM
It's got a 16lb cap which is what it had from factory. Sensor is located in the thermostat housing and should automatically bleed the air out of it because of the small notches in the top of the thermostat itself.
Plan right now is to replace the electric fan, temp sensor, and put a stronger mechanical fan clutch from a ZJ on it. I know that XJs don't have the best cooling system but there are also ones in a lot hotter places and carrying a lot more weight than I am that don't run at 220* just driving down the road.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on August 04, 2014, 07:06:06 AM
I'd bet there's an air bubble in the system. Park it on a really good incline and pull the upper hose.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 04, 2014, 08:19:49 AM
I'd bet there's an air bubble in the system. Park it on a really good incline and pull the upper hose.
Just pull the upper hose or pull and run it till coolant comes out? Also better to pull it from the radiator or from the thermostat housing?
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on August 04, 2014, 08:45:07 AM
too much glycol in the system can hurt too, but sounds like air
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on August 04, 2014, 09:21:47 AM
Drive it to the hill with the rad cap off so it doesn't build pressure. park WAY nose up (like 30-35Ëš) and see how much air you've got in the rad. I bet it's not plumb full.
In the future, maybe filling it at the cap nose-up like that could prove to be enough, but considering current circumstance, I'd pull the upper hose off and fill it at the block there if it's not plumb full. Get as much in there as you can, put the hose back on, and then get as much in there as you can.
Get it warmed up with the cap off, then tighten the cap for cooldown. That way you get maximum expansion when it heats and it will suck in from the overflow as it cools. If you have a cap that you can release pressure on, that can help with this game a LOT. I haven't proven it through years of use and mud exposure yet, but this has helped me bleed 571's system quickly and easily (I run a 24-26# cap. HD parts):
BTW - at 16psi, I'm pretty sure you would be boiling at 260 if it wasn't reading a bubble. Okay, I just found a chart that says plain water boils at 260 at 16psi. So actually you could be seeing an accurate reading there... But I still doubt it and think you have air.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 04, 2014, 05:41:08 PM
I did what you said Mike, drove it to an incline with the cap off. Didn't see anything other than 2 small little bubbles. Also got it warm with the cap off on the incline and shut it down/replaced the cap. Hopefully this helps a bit. Didn't drive it around afterwards because I was busy fixing the rear bumper and popping a dent in my rear quarter panel out (got my first "real" body damage yesterday ::) ), so I'll putz around with it tomorrow and see if it helped. Still plan on doing the ZJ clutch fan, temp sensor, and electric fan once I get prices from Arie. A friend of mine mentioned that the air/fuel ratio being off could be causing it to run hot as well. My o2 sensors are only 2 years old but I was having check engine lights come on for the o2 sensor heater, though no codes for the o2 sensor itself. Would that be something that could cause the engine to run hotter than normal?
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on August 04, 2014, 06:31:22 PM
inaccurate O2 readings could make it run richer (cooler) or leaner (hotter) than it should.
Title: Re: 1997 Jeep XJ Country
Post by: luvmyxj on August 06, 2014, 03:17:17 PM
can you feel coolant running through your hoses? if not your pump is bad or your coolant bottle cap isnt sealing right. correct me if im wrong but shouldnt the radiator cap be on in a closed system?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 06, 2014, 06:43:52 PM
can you feel coolant running through your hoses? if not your pump is bad or your coolant bottle cap isnt sealing right. correct me if im wrong but shouldnt the radiator cap be on in a closed system?
The hoses are definitely hot, and have coolant in them, I don't know so much about being able to actually feel coolant going through them (haven't really felt for that). Open systems still have a radiator cap.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 07, 2014, 04:38:44 PM
Just ordered the flowkooler water pump. After sitting here thinking that I'm gonna have it all apart, why not replace it just in case it is t he pump. If I new radiator, fan clutch, E fan, thermostat, hoses, temp sensor, and water pump don't help get this thing's temperatures back under control, I literally have no idea what else it could possibly be.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on August 07, 2014, 05:52:25 PM
Tuning.
Timing, spark quality, a/f ratio (lean is hot. Poor o2s, injectors, vac leaks).
I'd expect any of those would have to be way off to see a notable difference on a stockish setup though.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on August 08, 2014, 07:49:46 AM
97 would be smart enough to pop a light if any of those things were wrong.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 08, 2014, 09:01:39 AM
97 would be smart enough to pop a light if any of those things were wrong.
^That. I was looking at it last night and the bolts from the manifold flange to the rest of the exhaust were a little loose. Tightened them up just incase it was sucking in a little air and throwing the O2s off. Also ordered new plugs and wires, distributor cap, temp sensor, E fan, and O2s, gonna call NAPA today to get the ZJ fan clutch. If none of this fixes it, Mark's favorite solution of burning it might just be a viable option.
Title: Re: 1997 Jeep XJ Country
Post by: Wingman on August 08, 2014, 09:05:55 AM
Plus you have experience at burning things!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 15, 2014, 09:49:31 AM
Woo weekend projects. FlowKooler water pump, ZJ fan clutch, new E-fan, NTK O2 sensors, Champion Copper Plus plugs, Denso plug wires, distributor cap, coolant temp sensor, and serpentine belt. Also gotta run new brake lines all around on the pickup, gotta love when one bursts on you the week before you plan on towing down to Rausch.
True story. Really lucky honestly because the night before, I had just brought my friend's WJ back from Buffalo and that night we were just about to leave to take a horse to my Mom's friend's. Got everything loaded up, go to pull out and the pedal went right to the floor.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 18, 2014, 09:25:08 PM
Got everything installed this weekend and everything went pretty smoothly. Old pump came out without issue, I was crossing my fingers that the fins would be all chewed/rotted up. Unfortunately it looked like this.
That being said, the new pump and fan clutch definitely helped, a lot. I'm now idling at 210 and if I bump the RPM up to 1500, it drops to 207 (probably lower if I held it longer than 30 seconds). Going up a long hill, it never got to the next line after 210, if I had to guess, it might have hit 218. Still a little warmer than what I want, but a huge improvement over idling at 216 and hitting 240+ going up the same hill. I could probably put a 180* stat on it and it would get to where I want, but considering the one in it is brand new, Ill think about that for next time. It could just be non sense, but to me, I can see how my lack of proper gears could have an effect on it since I'm still at 3.55 and it has to work the motor harder to keep moving. Also the ZJ fan clutch wasn't nearly as loud as I thought it would be, I can definitely hear it more, but it's not roaring like everyone says. Don't have any pictures of the new stuff in, but there's nothing really to see. Tomorrow I gotta do brake lines on my pickup (figures a line bursts the week before I have to leave) and then I'm off to Rausch for 4 days as a birthday present for my self.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 25, 2014, 09:17:13 PM
Just got back from Rausch today. Things went very well this weekend, temps stayed right where I like them, and the XJ performed great. Couple things need tweaking like my shackle angle, need a new driver's seat, and my steering box is starting to leak a bit, but nothing major broken. Other than that, I had a ton of fun and can finally post some pictures of me wheeling this thing. (https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/s720x720/10649847_938582996157737_5383655030631614486_n.jpg)
This hill cost me my driver's seat :rolleyes: (https://scontent-a-ord.xx.fbcdn.net/hphotos-xpa1/t1.0-9/p180x540/10641075_10202638171538243_9079845856373264328_n.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on August 26, 2014, 08:57:53 AM
nice!!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on August 26, 2014, 10:17:24 AM
Video of me on Yellow Jacket
http://youtu.be/VfDFFXuS8O8
Title: Re: 1997 Jeep XJ Country
Post by: xjh3 on August 29, 2014, 10:05:19 PM
Sweet!!!
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 22, 2014, 03:06:27 PM
I really need to get this motor sorted out. Entire cooling system has been replaced, still running 220+ on the thruway. Only thing I can think of is a bad head gasket and/or cracked head, but I have no symptoms of it (no oil or coolant contamination). Need to do a compression test. Also getting spontaneous rough idle, but only when it's in park. Any other gear, it idles fine. Passenger side window isn't going up, even when using the driver's switch. I suspect that it's got something to do with the plugs when I take the doors off. Seat mount welds are broken, going to fix when I get a real seat, and the steering box is starting to leak out the bottom. Haven't decided if I want to get a replacement box and tap it for hydro assist or bite the bullet and get an entire kit from PSC.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on September 22, 2014, 03:59:48 PM
PSC is a waste of money. Stock replacement or a Durango box.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 22, 2014, 05:09:13 PM
I was kinda figuring that. I just felt that having a box purpose built to accept hydro assist might be worth it. That and I'd be nervous tapping my own box, but they seemed to be working out well enough for Spencer and Harrison.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on September 23, 2014, 08:39:51 AM
drill & tap is easy to do.
Title: Re: 1997 Jeep XJ Country
Post by: Spencer on September 23, 2014, 11:44:00 AM
i have $165 into my hydro assist including all hoses, fittings, ram. drill and tap was the way to go for sure.
durango box has less throw than the stock box. not worth the trade normally, and def not if doing hudro assist.
im worried about stock d30 knuckles and assist. i would do a wj knuckle swap with heims everywhere, if it was me. i hate TRE's. mine have 5-6 trips on them and are wasted.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 23, 2014, 04:45:44 PM
I've been reading about hydro assist and the currie steering I have. Most of what I've read say that the much beefier tie rod ends can handle it.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 23, 2014, 04:47:11 PM
Aside from the cross over steering, and the brakes, are the WJ knuckles them selves stronger?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on September 27, 2014, 10:39:18 AM
Just ran a compression test and I'm not to sure what to make of the results Cylinder 1 125 - 130 - 130 - 110 - 115 - 120 Cylinder 6
I'm gonna have a friend that owns a shop do one because I'm not sure how much I can trust the gauge I have (neighbors that he let me borrow) and get a second opinion. Cylinder 4 and 5 concern me because they are both below 120, are right next to each other, but are within the "30 psi maximum difference".
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 01, 2014, 12:03:44 PM
Getting really fucking tired of the heat issue with this thing. Took it too a shop for a compression test, multiple gauges all reading between 140 and 150 on all cylinders. Combining that with the fact that there is still no oil or coolant contamination, I think I can safely rule out the head/gasket. My only thoughts now is that the engine isn't getting enough air between the condenser and winch in combination with the engine working harder on stock gears with the 35s. I just wouldn't think it would be to the extent of the engine running as hot as it has been. The condenser is coming out this winter anyway since I'm converting the AC to OBA and 4.56s are happening next spring so we'll have to wait and see what happens then.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on October 01, 2014, 02:30:31 PM
try a 160 stat yet?
Ryans dakota got hot towing with just a light bar put up front! little things sometimes make huge difference over OEM setup
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 01, 2014, 03:52:49 PM
I have yet to try a lower temp stat. My stat is still opening and it never gets cool enough for it to close again. How would one that opens sooner help it? Because it opens sooner, does it over all open more than the 195 I have in it?
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on October 02, 2014, 07:24:33 AM
we notice a huge difference in the race car, but there is high load and recovery loads. a constant duty, no i dont think it would help much.
something has to be wrong you have to many new parts. give straight water a try next time the system gets dumped too. too much glycol is bad.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 02, 2014, 07:41:31 AM
we notice a huge difference in the race car, but there is high load and recovery loads. a constant duty, no i dont think it would help much.
something has to be wrong you have to many new parts. give straight water a try next time the system gets dumped too. too much glycol is bad.
I'll try that this weekend when I pull the AC condenser. Right now I should be running a 40/60 mix Antifreeze/water. I know something has to be wrong but I just can't remotely think of what it could be.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on October 02, 2014, 08:11:20 AM
XJs run warm to begin with. I'd expect improvement with the fancy rad and ventilation but I'd bet if you pulled the hood she'd be cooler. Or the winch. More air in/ more air through. Blocking air up front is a huge problem on the highway.
Tapatalking in traffic
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 02, 2014, 09:33:43 AM
XJs run warm to begin with. I'd expect improvement with the fancy rad and ventilation but I'd bet if you pulled the hood she'd be cooler. Or the winch. More air in/ more air through. Blocking air up front is a huge problem on the highway.
Tapatalking in traffic
The winch I'm sure isn't helping, even though it only covers a small amount of the grille since it sits down low in the bumper. I have hood vents, so heat/air extraction shouldn't be an issue. I'm pulling the condenser this weekend, hopefully it's that blocking enough air that it'll run cooler. The thing that bugs me the most is that there are other XJs out in the desert that run similar set ups to mine, only with stock cooling system components and run under 210.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on October 02, 2014, 01:01:48 PM
IR thermometer and check gauge accuracy?
Tapatalking in traffic
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 02, 2014, 03:11:10 PM
I haven't had an IR thermometer on it but I have checked with my scan tool to at least see that the computer is getting the same temp as what the gauge is reading.
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on October 06, 2014, 09:22:48 AM
Is that actually two sensors? Not sure if the cluster is just driven by that same reading.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 07, 2014, 06:49:40 AM
Early models have 2 sensors, later ones run off of one at the thermostat
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 13, 2014, 02:11:09 PM
Got the AC condenser out and things finished up today, also drained some coolant to add more water to is, I would guesstimate I'm running 70/30 water/glycol. Also added a bottle of water wetter for shits and giggles since I got it for free. Took it for a quick run and it wouldn't climb over 220 while going slow up a hill (probably more around 218), going flat and level it was barely a hair over 210. Granted it was only a quick run, that's a good improvement over what it was. Hopefully it keeps up like this, starting to put a list together for winter projects.
New driver's seat and mount Air tank and other stuff for OBA Chromoly axle shafts Real drive shafts New exhaust system from the header back (it's getting pretty beat) New fuel tank sending units and straps getting my gears installed
I'm sure there's more that I can't think of, but it's not nearly going to be as extensive as last winter, I want to get it out and wheel asap.
It's already gotten a new set of Falken Wildpeak ATs, but the truck is also gonna get a little TLC this winter.
Full tune up Finned dif cover and fresh gear oil some simple power adders (intake/exhaust?) Full brake job
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 21, 2014, 12:11:31 PM
Put this pile on the lift today to swap a drive shaft u joint only to discover that the shaft is toast. Have to beat the shit out of it with a hammer to get the slip to move, had to air hammer the slip off the splines. Cleaned, wire wheeled, cleaned again and re-greased it all and it still doesn't want to move. What ever, don't want to deal with it or another stock shaft, time to save up for a new one that's the proper length. It's the end of the year anyway, time to start gathering parts for projects this winter.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on October 24, 2014, 01:20:15 PM
Scored some disc brake stuff, backing plate and newish calipers, from a 97 zj to swap the drums off of my 8.25. Traded 2 rear axle shafts and a factory engine skid that were doing nothing but collecting dust for them.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 03, 2014, 08:48:32 AM
Was working under this thing today and noticed something weird. The leaf springs, which have only been installed since June, have an S bend in them. I have them bump stopped right so they don't go into negative arch at compression, and I wouldn't think they'd start sagging like this in less than a year. (https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t34.0-12/10841647_1000005986682104_1609959251_n.jpg?oh=9cc4bcf037d65d2ba53bdb2b360326ae&oe=548122AE&__gda__=1417820287_785206d8582e507333da7e51c3de49b7)
I contacted IRO about this and this was their response. "Some bending like this is actually normal, it doesn’t mean that the springs are no good or sagging. If you look at the springs with no weight on them they are actually really flat at the axle mounting area of the spring, not a perfect arch like most manufacturers springs. "
Am I the only one that thinks this is a BS response or is that actually perfectly normal?
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on December 03, 2014, 10:04:53 AM
That sure looks like a whooped spring to my eye - If they really are very flat I can imagine that potentially being normal though
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 03, 2014, 10:52:59 AM
That sure looks like a whooped spring to my eye - If they really are very flat I can imagine that potentially being normal though
This is how they looked the day I got them
(http://i.imgur.com/4Q1SIU2.jpg?1)
Title: Re: 1997 Jeep XJ Country
Post by: MrMindless on December 03, 2014, 11:25:36 AM
"If you look at the springs with no weight on them they are actually really flat at the axle mounting area of the spring, not a perfect arch like most manufacturers springs. " that's totally true.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on December 03, 2014, 02:47:55 PM
wow, thats weird. that must be a cluster to deal with people about. i would have called them shot without that new photo
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on December 03, 2014, 06:51:09 PM
wow, thats weird. that must be a cluster to deal with people about. i would have called them shot without that new photo
That's essentially how I was when I was looking at that. Talked to the "lead engineer", he also said that's how the springs are supposed to be and that it's fine, also said that other people have called about the same thing in the past. Will still honor the life time warranty on them basically no matter what.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on February 19, 2015, 11:37:19 AM
Been acquiring some goodies for this thing over the past couple months. Not nearly as much as I'd hoped to have had by now but shit happens.
50" Lifetime LED bar (http://i.imgur.com/vnZ6jIMl.jpg)
Synthetic line for the winch (http://i.imgur.com/S3itVjql.jpg)
Nitro Gear chromoly axle shafts for the front end. (http://i.imgur.com/GwNhDvkl.jpg)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on March 20, 2015, 12:29:15 PM
Got my 50" Light bar mounted this afternoon. Thanks again Ryan.
(http://i.imgur.com/oUxtEM3.jpg?1)
Title: Re: 1997 Jeep XJ Country
Post by: Ryan_25 on March 23, 2015, 07:42:08 AM
Looks great.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on May 21, 2015, 04:05:31 PM
Haven't really updated recently, so here's what's happened in the past month. Lightbar wired up, 4.56 gears installed, and swapped the rear drums out for disc brakes. Also got my ORFab rear quarter armor installed. (http://i.imgur.com/xr1yir8.jpg?1)
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 01, 2015, 08:18:13 AM
Got my Corbeau seat installed on the driver's side this weekend. Had to completely re build the mounting bracket and do some heavy massaging to the trans tunnel to get it to sit low enough for my height. Over all I'm really happy with it, it's more comfortable and much more supportive than my factory broken seats. Still have to get an adapter bracket for the passenger side to get the other one in. (http://i.imgur.com/h5ArfGP.jpg?1)
Title: Re: 1997 Jeep XJ Country
Post by: s0l0ithz on June 01, 2015, 10:05:06 AM
Those ones recline? What model are they?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 01, 2015, 10:19:18 AM
Yeah it reclines. It's a Corbeau Baja RS.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on June 01, 2015, 04:46:37 PM
nice work josh, how long did it take you to do it?
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 01, 2015, 06:31:52 PM
All together about 4 or 5 hours, though a good portion of that was spent shooting the shit, lunch, trying to get my friend's shitty 110 mig to work, and just staring at me sitting in it. We abandoned the idea of building a new forward seat mount. Cut the back parts of the bracket down using the original mounting locations and bent the forward parts out and bolted them straight to the floor with a plate on the bottom to reenforce it.
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on June 24, 2015, 05:17:24 PM
Got a lot done this week. Front frame stiffeners have been welded in, passenger seat prepped and the new Corbeau Baja just needs to be bolted in, front axle pushed an inch forward, new UCA bushings, and new upper bump stops. I have an Nth Degree engine oil skid coming because I have a few nasty dents on the oil pan and I feel I'm just on borrowed time with leaving it be. There's some dents on my transmission pan too, I'd like to eventually figure out a way to cover that as well, perhaps modify the oil pan skid to cover and connect back to my belly pan. I also did some things to my flat bed as well, new LED tail and marker lights and a new 7 pin plug so they actually work now, it'll also be getting some new tires shortly as the current ones are all sorts of dry rotted.
Title: Re: 1997 Jeep XJ Country
Post by: smichaelR22 on June 29, 2015, 01:30:07 PM
call jared for some gladiators and be done with tires for a while
Title: Re: 1997 Jeep XJ Country
Post by: Callelle on July 01, 2015, 11:53:36 AM
