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Unread 07-27-2014, 06:12 PM   #1
biggn235
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biggn235's XJ Sport build III

Alright it was inevitable, but I'm back with another XJ.

Specs-

'94 Cherokee XJ Sport 2 door
4.0
AW4
NP231
HP30/8.25
Rebuilt engine
Some terrible, crappy lift installed
15x10 American Racing wheels
33x12.5 Mastercraft Courser MT
Factory grill guard





It had been sitting for three years, and even though it started right up with a jump and was able to drive, it needs some work. As you can see from the photos- it was leaking fuel from the rear and water from the front, the brakes are locked up and it was starting to overheat. So rather than try to limp it 50 miles home, I left it in a Target parking lot and came back the next day with a truck and trailer.





Home in the shop.



Has no carpet, headliner, or radio.



List of things it needs to be street driveable, reliable, and relatively safe-

Fuel tank -ordered 7/27 -finished
Fuel filters -ordered 7/27 -finished
Fuel vent gaskets -ordered 7/27 -finished
Fuel pump gasket -ordered 7/27 -finished
Filler and vent hoses -ordered 7/27 -finished
New brake lines -ordered YJ lines 7/27 -finished
Pump/pickup/sending unit assembly -given 8/11 -finished
New rubber fuel lines -purchased 8/15 -finished
Rotors -ordered 8/7 -finished
Calipers -ordered 8/7 -finished
Pads -ordered 8/7 -finished
Radiator -ordered 8/7 -finished
Coolant fill tank -ordered 8/7 -finished
Radiator hoses -ordered 8/7 -finished
Thermostat -ordered 8/7 -finished
Trans/t-case fluid
TC drop
Clean NSS
Fix horn
Fix signals -finished
Replace muffler
Replace windshield
Replace driver side window -finished

More updates coming, I was able to get some work done already. Let me know what you think

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Unread 07-27-2014, 06:15 PM   #2
Teej
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Your last build was one of my favorites on here. Glad to see you back, man!
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Unread 07-27-2014, 06:28 PM   #3
biggn235
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Glad to be back! This XJ will not be taking on daily driver duties, so I'll actually be able to take my time while working on it and compromise less.
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Unread 07-27-2014, 06:30 PM   #4
Teej
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Quote:
Originally Posted by biggn235 View Post
Glad to be back! This XJ will not be taking on daily driver duties, so I'll actually be able to take my time while working on it and compromise less.
Whatever you do, get Goodyear MT/Rs for tires.
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Unread 07-27-2014, 06:31 PM   #5
biggn235
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The Mastercraft's are brand new so I'll be running them for awhile. Pretty sure they are out of round from sitting so long though... So we'll see haha.
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Unread 07-27-2014, 06:44 PM   #6
V1GiLaNtE
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AWWWW YEAAAA.

Welcome back!
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Unread 07-27-2014, 08:23 PM   #7
MOBBiN
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Seems like a common theme. Sell the xj, try something else then return to the xj. Welcome back! I like the wj also
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Unread 07-27-2014, 09:02 PM   #8
biggn235
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AWWWW YEAAAA.

Welcome back!
Thank you!

Quote:
Originally Posted by MOBBiN View Post
Seems like a common theme. Sell the xj, try something else then return to the xj. Welcome back! I like the wj also
Haha yeah I can't get away from them. Since my last XJ I've graduated college and gotten a good job, so now I'll actually have some money to dump into it.
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Unread 07-31-2014, 07:41 PM   #9
biggn235
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Alright so the previous owner was very incompetent when it came to replacing the fuel pump, he didn't use a tank seal when reinstalling the assembly so it caused gas to leak everywhere.



Since the Jeep was sitting for so long lots of critters made their home under it.



Cleaned off the dirt daubers and got to work dropping the tank.



Mud was caked all inside the fill tube shield.



Pump assembly and filter off and draining.



Tank out.



The tank was completed rusted out, this was the color of the gas.



Kept this guy close.

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Unread 07-31-2014, 07:43 PM   #10
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Amazingly the 4.0 still ran fine with that crappy gas. I've always said if you could figure out a way to pour coal into the tank, the 4.0 would run on it.
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Unread 07-31-2014, 07:47 PM   #11
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New tank arrived today. Still waiting on some other parts to get here before I throw it all together again.

Went over all suspension bolts with this. Getting ready.



Lots of room with the tank gone. While its out I'm going to paint everything underneath.



Cleaning out the rear brakes as well.



Sorry for the blurry pics. Cell phone doesn't do well in low light.









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Unread 07-31-2014, 08:35 PM   #12
VegasGT
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So glad to see you back in an XJ dude!
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Unread 07-31-2014, 08:53 PM   #13
biggn235
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So glad to see you back in an XJ dude!
It just feels right
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Unread 08-02-2014, 07:04 AM   #14
my1979impala
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You have 2 weeks till I'm done. Work faster! Lol. Ps do you want an extra fuel pump assembly? I pulled the one from that xj I parted and I have no use for it.
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Unread 08-02-2014, 10:52 AM   #15
biggn235
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You have 2 weeks till I'm done. Work faster! Lol. Ps do you want an extra fuel pump assembly? I pulled the one from that xj I parted and I have no use for it.
Is the sending unit intact? What does the power wire coming off the assembly look like?
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