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Unread 07-17-2012, 10:58 PM   #1
JeepsOLot
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Project Commuter Commando

Well, I guess this will be my XJ "build". I'm originally from the YJ/CJ forums because of my CJ9 build, then, on to the WJ forum when I got an '04 WJ for my wife. Next up, a commuter XJ that looks different, but, functional.

I got this '93 XJ from Mean Max in the YJ forums for $600.











It's a '93 Country, 2WD, with 4.0L and AW4 with 169K miles. Not sure of the rear axle, probably the D35, not hopeful!

What I want from this Jeep: a bullet-proof commuter, but, the looks of a moderate wheeler. I have two 4WD Jeeps, thought I would give a 2WD Jeep a chance, and they are cheaper. Above all else, I want reliability and good parts availability, hence why I didn't want the pre-'91 Renix. I wanted a 4.0L, since my two other Jeeps have the 4.0L as well. I really wanted the AX15, but, this Jeep came at a good price.

The poor thing had been sitting at Mean Max's shop for a few months. He bought it knowing that the AW4 was bad. In the next few months, a couple of parts were taken off here, a few parts there. It was time for me to get a better Jeep suitable for commuting then the CJ9, plus the CJ was getting a little run-down at 256K miles. I didn't have the extra money to put into it because of having 2 car payments. Well, after selling one vehicle (non-Jeep), I had money. Getting this XJ for cheap and fixing it up with NO CAR PAYMENTS, was a no brainer!

Things I want to do: getting an AW4 from a '99 XJ, get the few missing parts back, a small lift to fit 31's under it, depending on what rear axle is underneath, put an 8.8 or D44 in it, swap the front to a '97+ front OR a Wagoneer grille. and a paint job. I'm not sure what else I want to do with it, figure it out as I go alone. Comments welcome, as this is my first adventure into Cherokees.

Jerry

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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-18-2012, 06:24 AM   #2
Texsun
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I recommend you just swapping a c8.25. Especially if you dont plan on wheeling it, plus they are cheap and OEM to allot of XJs. They are also rather tough, comparable to d44 some might say
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Unread 07-18-2012, 07:36 AM   #3
JeepsOLot
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Never heard anyone talk about the 8.25, up or down. I really don't care as lone as there isn't a D35 under there, and this is coming from a guy that ran a D35 for over 200k with no problems. I just don't want the "what if" to happen.

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-18-2012, 08:32 AM   #4
weboneando
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Quote:
Originally Posted by JeepsOLot View Post
Never heard anyone talk about the 8.25, up or down.
Sure there is a lot info about it here at the forum, and IMO it´s a great axle for a 2WD and DD
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Unread 07-18-2012, 10:22 AM   #5
JeepsOLot
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What years would that axle be in? I know my friend's '96 XJ has the 8.25, how far back did they put that axle in the XJ?

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-18-2012, 10:33 AM   #6
ibjeepin95
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I like the pimpin' woodgrain.
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Unread 07-18-2012, 05:01 PM   #7
wj_paperboy
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Quote:
Originally Posted by JeepsOLot
I know my friend's '96 XJ has the 8.25, how far back did they put that axle in the XJ?
The 8.25 started in 1991, in 1997 chrysler upgraded the splines to 29. They can be found in both XJ's and Liberties. Liberties have disc brakes. There are threads about swaps here on the forum.

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Unread 07-18-2012, 06:29 PM   #8
JeepsOLot
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Hey, Ibjeepin95, I LIKE my woodgrain, LOL!

Here are a few more pics:




Another hillbilly "fix". Not exactly sure how to handle these, one on each side. Should I dig the crap out and start over, or, just clean, sand, and smooth, then paint?


Here's a beautiful pic, an 8.25 rear axle!! Still need to find out what ratio it is.


Is this a factory hitch? It looks like a WJ factory hitch.


The back seat area, minus all of the crap that was there.



More pics of the front seat area and dash:



Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-19-2012, 08:13 PM   #9
JeepsOLot
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I did some checking out of the electrical systems on it. Most of the lights work, all of the interior lights work, but, for the exterior lights, found a bad bulb in the rear driver side brake/tail light. The turn signals/hazards work, and the brake/running lights work(except for the driver's side). The front and rear wipers work, as do both remote mirrors. All of the door locks work, some do need some grease.

For the windows, only both driver's side windows work. I'm not exactly sure what's going on, only that the front passenger side doesn't do anything, and the rear passenger side sounds like it wants to close (the window is already closed), but nothing going down. The one thing that told me that something was up with the windows was the window motor I found in the glove box! would there be anything that would cause both windows on one side to go out like that?

One other thing, what is this sensor for?


Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-22-2012, 06:50 PM   #10
JeepsOLot
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Ok, trying to figure out everything I need to get this thing on the road. This is the tranny from a '99 XJ that I might be putting in it, assuming the tranny that's in it now really is bad.



What would I need to swap this over to the '93? I think I need to swap the tail housing so the speedo sensor would work.

So far, I need a mechanical fan and a set of tranny lines between the tranny and radiator to get it running to see what else it needs. The mechanical fan was used on my friend's customer's Cherokee. The tranny lines, the bonehead that supposedly was checking out the tranny, bent the lines AROUND the front axle, making them useless! The dipstick tube for the tranny was in the back of the Jeep, and the wiring for the TCM was wrapped around the tranny. I installed the dipstick tube and plugged the wires where they were supposed to be. I hooked up the throttle cable from the tranny, but, the cruise cable couldn't be hooked up as the plastic piece that attached to the throttle plate broke.

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 07-22-2012, 07:03 PM   #11
JeepsOLot
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I got a few things done today, got the tail light on the driver's side working, just a dead bulb. I sanded down the areas on the rear of the roof and sprayed some paint there. I also painted the headlight bezels, now, they're black instead of gray, and match the grille.

The tail lights:



The brake lights:



The roof sections:



The headlight bezels:




The thing is to get the parts I need to get this thing running, then, I'll go from there.

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 08-13-2012, 09:37 PM   #12
JeepsOLot
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My friend Max that I'm buying the XJ from had to take the mechanical fan off for one of his customers, this was before I was interested in it. He said that he would get me another fan, no problem. Well, I was looking it over, and found a corroded/leak area on the bottom of the radiator, so, great, I need a radiator. I told max about the radiator, and he said he had a new one in his shop, and he would give it to me, but, I would be on my own for the mechanical fan. I said DEAL!! I put that in, and got a mechanical fan for $25 at the U Pull and Pay, Sweet!!

Every plug on the tranny was unplugged, so, I had to trace every one and hook those up. Then, came the tranny cooler lines, ahhhhhh!!

Here was what they looked like when I first saw the Jeep:


Now, mind you the other ends of those cooler lines are ATTACHED TO THE RADIATOR!!!! The ends that you see in the pic are supposed to go to the tranny!!! Who does this!?!? There is no reason why someone would bend them all the way to the front and around the front axle!! Eventually, I will be getting new lines, but, I was able straighten them out without kinking them, go me!!

Anyway, like I said, I put a new radiator in, a used mechanical fan, and another starter. The Jeep came with 3 starters!! One I used for my CJ, one was bad, and the last one was the charm. I topped off the tranny fluid and rechecked the coolant after the radiator change.

I was able to fire her up, finally!!!



The sad thing was that I was tired at this point, and I didn't do so well in placing the phone. You can hear the engine a little, but, you mostly hear that aux electric fan, grrrr!! Found out that I probably have a missing O-ring in one of the tranny side fittings of the cooler lines, but, other then that, it was a success!!

The next things to do are get a battery (I used the CJ's battery for this test), drill out a broken bolt in the rear axle yoke, fix the leaking tranny line fitting, find nuts for the exhaust header flange, and find bolts for the shifter cable bracket on the tranny so I can hook the shifter up, and THEN, she'll be ready for a road test. I hope the tranny is ok, and it's just a TPS or other simple sensor issue, but, I have another tranny I can put in there if the need arises.

That's it for now!!

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 08-18-2012, 06:29 PM   #13
JeepsOLot
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Well, after replacing an o-ring for one of the tranny lines, extending the battery cables so I could actually install a battery in the Jeep, topped off the tranny fluid as well as the coolant, I attempted to move the Cherokee for the first time under it's own power in over 2 years!



There are still a few issues that need working out. I need to figure out why it seems to be out of time, yet, there seems to be no way of actually adjusting it. It gets to a certain RPM, and struggles to rev higher. I need to drill out a broken drive shaft strap bolt before I can do a road test to see if the tranny is good or not.

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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Unread 08-18-2012, 10:48 PM   #14
tehshoemaker
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Quote:
Originally Posted by JeepsOLot View Post
I did some checking out of the electrical systems on it. Most of the lights work, all of the interior lights work, but, for the exterior lights, found a bad bulb in the rear driver side brake/tail light. The turn signals/hazards work, and the brake/running lights work(except for the driver's side). The front and rear wipers work, as do both remote mirrors. All of the door locks work, some do need some grease.

For the windows, only both driver's side windows work. I'm not exactly sure what's going on, only that the front passenger side doesn't do anything, and the rear passenger side sounds like it wants to close (the window is already closed), but nothing going down. The one thing that told me that something was up with the windows was the window motor I found in the glove box! would there be anything that would cause both windows on one side to go out like that?

One other thing, what is this sensor for?


Jerry
that is the sensor for the key fob to lock/unlock
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Unread 08-19-2012, 07:12 AM   #15
JeepsOLot
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Yep, I know now, I just have to get a couple of fobs to work with it. Right now, there are more pressing things to take care of. I'm replacing the Fuel filter as well as running some injector cleaner in the tank today. I will also be drilling out that bolt in the rear axle yoke, retap it, then finish bolting up the rear drive shaft.

Jerry
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1992 Jeep "CJ9" (YJ with '78 CJ front clip, '80 CJ Tailgate, Custom CJ Dash with '76 CJ Gauges) AX-15 from a '93 YJ, 2.5" Rancho SL, 5/8" MORE booms, 1" BL, and 33"x10.50" SS TSL's
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