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Unread 12-05-2012, 09:01 PM   #16
Skerr
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Can anyone confirm these parts for me? I was doing some research, and I think this is what we have as far as drivetrain.

Front Axle- HP D30
Rear Axle- D35 C-Clip, 3.73 gears
AW4 tranny (Novak says it's okay, but not great- what are my options?)
NP231 Tcase

I have a tranny cooler in front of the radiator, a hitch, and the plug-in for towing on the bumper. Does this mean I have the tow package? If so, then I have 3.73 gears. If not, then probably 3.55.

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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
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http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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Unread 12-05-2012, 09:41 PM   #17
dmill89
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Quote:
Originally Posted by Skerr View Post
Can anyone confirm these parts for me? I was doing some research, and I think this is what we have as far as drivetrain.

Front Axle- HP D30
Rear Axle- D35 C-Clip, 3.73 gears
AW4 tranny (Novak says it's okay, but not great- what are my options?)
NP231 Tcase

I have a tranny cooler in front of the radiator, a hitch, and the plug-in for towing on the bumper. Does this mean I have the tow package? If so, then I have 3.73 gears. If not, then probably 3.55.
Don't worry about the AW4 it's probably the most reliable automatic transmission Jeep has used in the last 20 years (with the possible exception of the Daimler transmissions in newer Jeeps) and is definitely the best automatic mated to the 4.0L I6, the others of that era were the Chrysler TF999, 32RH, 42RH/RE, and 42RLE. The old 3 speed torque flights (TF999, 32RH) are reliable but horribly inefficient, the 42RH/RE lacks reliability, and the 42RLE is a complete piece of garbage like the rest of the ultra-drive series lacking performance and reliability, and is derived from an front-wheel-drive car transmission the 42LE from the LH cars (Chrysler Concorde/ Dodge Intrepid).

The AW4 is basically identical to the A340 used in 4Runners and Toyota trucks but with different electronics to interface with the AMC/Chrysler PCM. The only real flaw with the AW4 is that it is inefficient but so are most other early electronic automatics and non-electronic autos are even worse but the 4.0L I6 has more than enough power to move an XJ so losing a little bit of it to the transmission isn't a big deal. Unless you really want a manual leave it and just make sure to change the fluid on schedule and use DexronIII/Mercon (since this is an Aisin transmission it does not use ATF+4 like most Chrysler transmissions do). On the off chance it fails you can get a used one with less than 100k mi on it for around $300.

If it is AWD (Has a full time setting) as stated in the first post the transfer case is an NP242, the 231 is 4WD (Part time only).

The front axle in all XJs is the D30, HP 1999 and older, LP 2000-2001.

You can tell which rear axle it has based on shape, the D35 is oval, the Chrysler 8.25" has a flat top and bottom, the Dana 44 has flat sides and is non-symmetrical when split down the middle (curve is higher/lower on left side when looking from behind). The Chrysler 8.25" and Dana 44 are much stronger than the Dana 35 and would be recommended for 33" or 35" tires but the D35 is sufficient for the stock configuration.
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Unread 12-06-2012, 06:30 AM   #18
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Quote:
Originally Posted by dmill89 View Post
Don't worry about the AW4 it's probably the most reliable automatic transmission Jeep has used in the last 20 years (with the possible exception of the Daimler transmissions in newer Jeeps) and is definitely the best automatic mated to the 4.0L I6, the others of that era were the Chrysler TF999, 32RH, 42RH/RE, and 42RLE. The old 3 speed torque flights (TF999, 32RH) are reliable but horribly inefficient, the 42RH/RE lacks reliability, and the 42RLE is a complete piece of garbage like the rest of the ultra-drive series lacking performance and reliability, and is derived from an front-wheel-drive car transmission the 42LE from the LH cars (Chrysler Concorde/ Dodge Intrepid).

The AW4 is basically identical to the A340 used in 4Runners and Toyota trucks but with different electronics to interface with the AMC/Chrysler PCM. The only real flaw with the AW4 is that it is inefficient but so are most other early electronic automatics and non-electronic autos are even worse but the 4.0L I6 has more than enough power to move an XJ so losing a little bit of it to the transmission isn't a big deal. Unless you really want a manual leave it and just make sure to change the fluid on schedule and use DexronIII/Mercon (since this is an Aisin transmission it does not use ATF+4 like most Chrysler transmissions do). On the off chance it fails you can get a used one with less than 100k mi on it for around $300.

If it is AWD (Has a full time setting) as stated in the first post the transfer case is an NP242, the 231 is 4WD (Part time only).

The front axle in all XJs is the D30, HP 1999 and older, LP 2000-2001.

You can tell which rear axle it has based on shape, the D35 is oval, the Chrysler 8.25" has a flat top and bottom, the Dana 44 has flat sides and is non-symmetrical when split down the middle (curve is higher/lower on left side when looking from behind). The Chrysler 8.25" and Dana 44 are much stronger than the Dana 35 and would be recommended for 33" or 35" tires but the D35 is sufficient for the stock configuration.
Glad to hear the AW4 is a useable tranny. I was concerned that it wasn't going to fit the bill, and that I was going to have to go with a THxxx of some kind.

I am confused over the AWD scenario. There are no lockouts on this Jeep, so that means I am in 4WD all the time... right? And by placing the tranny/tcase in 4WD it engages the front driveshaft? So is this considered part-time or full-time? I'll get some pics posted up to help clarify things.

Have a lead on a lift at the JY. Going to check it out this afternoon.
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Unread 12-06-2012, 07:33 AM   #19
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Yeah, yeah, I know... too many questions! Sorry, Guys. I'm trying to get answers the short way. I just don't have hours to sit in front of the computer to get all of the info I need/want, so I'm coming to the experts.

I have a line on a suspension lift at the JY. The owner said he would pull the lift for $50, or the lift and rear axle for $200. We are headed there now to confirm that this Cherokee does, indeed, have lift springs.

My question... here is the pic of the rear axle of Fallon's XJ. Is this the poor D35 C-Clip rear end, or is this the Chrysler? I don't want to buy the rear end if it is not an upgrade.

Thanks
cimg0156_1.jpg  
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

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Unread 12-06-2012, 10:39 AM   #20
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The JY suspension lift turned out to be lift blocks under factory springs, so I didn't get it. We did, however, find a good rear view mirror, hand hold for inside the cab, and the rubber tubing for the PCV system. So it wasn't a total loss of day. Plus, we stopped and got some tranny fluid and new shocks. Tranny shifts like a charm now!
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

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Unread 12-06-2012, 10:45 AM   #21
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Just some pics...

Has anyone ever repaired the rust under the windshield? How did you do it?
cimg0157_1.jpg   cimg0158_1.jpg   cimg0159_1.jpg   cimg0165_1.jpg   cimg0162_1.jpg  

cimg0166_1.jpg   cimg0167_1.jpg  
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

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http://www.jeepforum.com/forum/f8/cl...hread-1061897/
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Unread 12-06-2012, 10:46 AM   #22
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Originally Posted by Skerr View Post
Yeah, yeah, I know... too many questions! Sorry, Guys. I'm trying to get answers the short way. I just don't have hours to sit in front of the computer to get all of the info I need/want, so I'm coming to the experts.

I have a line on a suspension lift at the JY. The owner said he would pull the lift for $50, or the lift and rear axle for $200. We are headed there now to confirm that this Cherokee does, indeed, have lift springs.

My question... here is the pic of the rear axle of Fallon's XJ. Is this the poor D35 C-Clip rear end, or is this the Chrysler? I don't want to buy the rear end if it is not an upgrade.

Thanks
Unless the jack is covering up the flat part I would say thats a d35.

Everyone says they are horrible. That said my brother has been wheeling one on 35's for a year now and never an issue.

Your call.
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Unread 12-06-2012, 11:05 AM   #23
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Unless the jack is covering up the flat part I would say thats a d35.

Everyone says they are horrible. That said my brother has been wheeling one on 35's for a year now and never an issue.

Your call.
Nope, no flat spot. I agree a D35. Good to know we can run this axle for awhile yet. Thanks for the feedback.
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

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http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
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Unread 12-06-2012, 01:10 PM   #24
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Subed like watching builds like this!
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Unread 12-06-2012, 01:53 PM   #25
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Originally Posted by Skerr View Post
[snip]
I am confused over the AWD scenario. There are no lockouts on this Jeep, so that means I am in 4WD all the time... right? And by placing the tranny/tcase in 4WD it engages the front driveshaft? So is this considered part-time or full-time? I'll get some pics posted up to help clarify things.
You have Part-Time 4WD. DO NOT DRIVE ON PAVEMENT IN 4WD HI OR LOW.
Unless you have a vacuum disconnect D30, your drive shaft is always driven by the differential but you are not in 4WD until you engage it.
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Unread 12-06-2012, 01:53 PM   #26
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Subed like watching builds like this!
Quite an honor to have you join us. Thank you, Sir... or Ma'am!


New shocks, GabrielPro, make a WORLD of difference! My God... so sweet to drive. Smooth. And FAST! Dang, I like this 4.0.

I think we'll build a roof rack next, encompassing the rust that has formed up top. Probably use square tubing, but not a for-sure thing. Gotta find someone who can make the corners for us. Anybody use the the HF bender for small stock/square tubing with success? I have already been there with the roll cage on the CJ, trying to bend DOM tubing.
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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Unread 12-19-2012, 02:38 PM   #27
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Quote:
Originally Posted by sAe23 View Post
You have Part-Time 4WD. DO NOT DRIVE ON PAVEMENT IN 4WD HI OR LOW.
Unless you have a vacuum disconnect D30, your drive shaft is always driven by the differential but you are not in 4WD until you engage it.
sAe23... sorry I never saw your post. Thank you for this information.



Here is a little bit of meat and taters! Starting to get into the repair of this truck. We are cutting out the bad spots and welding in new metal. My son, Clay, is a certified welder. And my other son, Fallon, is a willing wrench-twister!

Here are the 4 corners of the roof after the roof rack has been removed.





I want to remove the rusted metal and weld in new metal. Clay is cutting out the rotten stuff with a die-grinder.


Another angle of Clay, and my youngest wire-wheeling some bolts for another project. it's GREAT to have kids!


First cut.


First patch. The "foot" of the roof rack will cover over these repaired areas.


HOW do you remove the lift gate hinges?


Clay on the creeper, Fallon kneeling next to him... trying to remove the rear bumper. The BUMPER is a CHALLENGE!!!! I am wanting to save it in case someone needs a nice chrome bumper, but I am leaning toward taking a cut-off wheel to it. We can't get to the bolts, and they are rusted into mutated lumps. Is it worth saving? Anybody need one?


Here are the plastic corners. Same concern... anybody need the corners? We will be making front and rear bumpers for this heep.




That's all for now. Mama has plans for us this evening. Going to see Christmas lights! I always grumble about it, but I end up enjoying myself!
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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Unread 12-20-2012, 12:45 PM   #28
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Got a little side-tracked! My youngest are active in 4-H, and they will be showing hogs in the county fair in January. Here are some pics of the pigs we picked up today and of the boys prepping the pen. Just some fun stuff if anybody is interested...
cimg0218_1.jpg   cimg0225_1.jpg   cimg0228_1.jpg   cimg0231_1.jpg   cimg0220_1.jpg  

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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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Unread 12-30-2012, 12:06 AM   #29
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We finished cutting out and welding up the rust holes in the roof. The patches are okay, but they sure warped a TON! I'm guessing I can smooth them out once I remove the headliner. I plan to build and install some kind of rack on top, and my mental picture includes a foot that will cover these areas, so I'm not TOO concerned. Yet, you know how plans change...

Is there a trick to removing the hinges for the lift gate? I have some rust there too, and I don't want to ruin the covers by experimenting.
cimg0219_1.jpg   cimg0220_1.jpg   cimg0221_1.jpg   cimg0222_1.jpg  
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
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Unread 01-01-2013, 12:49 PM   #30
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Injector Swap

I spent about 4 hours at the JY yesterday with the idea of pulling Neon injectors for the 4.0L swap. There is a ton of info about this swap, and I, apparently, had it swimming around in my head! The JY owner had 3 Neons, but only one had an engine. I easily pulled those injectors and I moved to the Stratus sitting next to it. It had the same 2.0L engine, so I pulled those injectors only to find they are single ported (one hole for atomization). So I left them there. I looked around for a 5.0 Ford, but I saw a line of Taurus cars. I have the impression that the injectors from the 3.0L Taurus is the Coup de Gras, and I went after them. I had to remove the plenum on top of the engine to get at the injectors. It took awhile, but Hey, if you want the good stuff, you have to work for it... right? I managed to remove the first fuel rail only to find that these injectors, also, were single ported. Bummer! A total waste of time! So I went over to one of the dozen or so Cherokees sitting in the yard. I wanted a spare fuel rail. The 2nd XJ I checked still had one, with injectors, so I pulled it. I was thinking that these factory injectors would be better than what is on my son's XJ as he has a leak or two. I got out of there with 10 injectors and a fuel rail for $40, which I thought was outstanding!

And that brings us to this morning. I was going to change out the leaking injector (it leaks badly) with one of the XJ injectors on the fuel rail. I thought I would take pics for your viewing pleasure! But guess what? Total bust. Wrong connectors!! So I need to go back and read again. Here's the pics.

Neon injectors that I pulled.



Close up of the numbers.



Wrong connector! This is USCAR type. I didn't notice this.



Fuel rail from 4.0L with factory injectors.



Just a close up of the XJ injectors...



Showing the single port for atomization. Still XJ.



I'm betting this XJ ran poorly!!



This is also the USCAR connector. I need to go back and determine what year this changed. Plain stupid!



Fuel rail on my son's XJ. PB wouldn't let me rotate the pic!! Grrr...



This is number 4 from the front. It leaks like a sieve! I wanted to at least change this out.


Jet tronics/mini timer connector... what I have on the '90 XJ.



A comparison of the two together.
JT/MT

USCAR



Back to the drawing board!
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
Fallon (and Dad) Build Thread
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