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-   -   1998 5.9 Build - Jeep #3 (http://www.jeepforum.com/forum/f22/1998-5-9-build-jeep-3-a-1145327/)

csouers 12-25-2010 11:56 PM

1998 5.9 Build - Jeep #3
 
Updated 9-5-2013

Specs:
1998 Grand Cherokee 5.9 Limited
236k miles
Bright Platinum Metallic Paint
Ultrastar wheels
235-70-R16 Firestone Destination LE2
46RE Transmission
Dana 44a with Working LSD
NP-242 Transfer Case


Jeep Modification/Repair List Since Purchase

Engine:
- OEM Jeep PCV Valve
- Valve Cover Gaskets
- New Crankcase Vent Grommet and Element
- Idler and Belt Tensioner Pulleys
- Napa serpentine belt
- Goodyear Gatorback serpentine belt (Napa squealed even after warranty replacement)
- Dorman Harmonic Balancer
- Oil filter adapter gasket
- Oil pan gasket
- Rear main seal

Fuel + Ignition:
- Napa/Belden spark plug wires
- Napa/Belden distributor cap and rotor
- Champion Platinum spark plugs
- NGK 2756 copper spark plugs (Installed while diagnosing pinging. One range colder than OE spec)
- 4-hole Fuel Injector upgrade. Sourced as a flowmatched kit from eBay

Cooling System:
- Radiator from radiatorbarn.com
- Upper and Lower hoses for a 5.2 cut to fit 5.9 Electric Fan coolant temp switches
- Stant Radiator Cap
- Stant 195* Thermostat
- ACDelco Water Pump
- VDO fan motor replacement with Motorcraft pigtail. Plug and play replacement.

Intake + Exhaust:
- Intake Manifold Plenum Pan aluminum replacement with Fel-Pro gaskets.
- New Intake Air and Coolant Temperature sensors
- Exhaust Manifold Gaskets
- NTK Oxygen Sensors
- 3" Magnaflow Catalytic Convertor
- 3" Magnaflow Muffler
- OE Tail Pipe

Transmission:
Rebuild 1
- Replaced some steel discs and all soft parts.
- Overdrive disassembled and rebuilt with new clutches.
- New torque convertor
Rebuild 2
- Would not hold pressure in 3rd. Would downshift into second until throttle valve pressure was applied and when slam into gear. Diagnosed as too much endplay. - - Seal rings would not hold be in correct location. Rebuilt at almost minimum play spec with larger spacer rings.
- New torque convertor per warranty.
- Overdrive housing replaced due to bearing snap ring wearing into housing.

Transfer Case:
NP242 (from 97 ZJ 4.0)
- Full Rebuild and Direct Swap
- VIC wiring connector change
- Linkage rebuild kit for XJ. New bushings and center support bearing.
- Rear Driveshaft shortened 1" to accommodate longer rear transfer case output, rebalanced and new 1330 Spicer U-Joints.
- Transfer case not modified as it would not solve the interference issue (common misconception)

Front D30:
- Carrier bearings
- Dorman Reman CV Shafts
- Timken/Precision Hubs

Rear D44a:
- Full overhaul, w/o LSD rebuild (functions 100%)
- Installed a set of used axle shafts. Mine were wore out by the wheel bearings.

Brakes:
- PowerStop Brake Pads F+R
- Raybestos Advanced Technology Rotors

Steering & Suspension:
-Front-
- Spicer Ball Joints
- Moog trackbar
- Moog upper/lower control arms
- Monroe steering stabilizer
- Mevotech greasable sway bar end links
- Mevotech 26mm swaybar frame brushings
- Monroe Sensamatic Shock Absorbers

Electronics:
- Crown E-Code Headlamps
- PIAA H4 Bulbs
- Headlight Relay Harness (bypasses factory wiring for more voltage to bulbs)
- Clear Front Corner Parking Lamps
- Alpine Head Unit iPod/MP3/CD/AM/FM
- Boss Sub Amplifier (very small)
- 1980 era Subwoofer
- Infinity Reference speakers in Front Doors and Sound Bar. Rear Door speakers removed.
- Bulldog Remote Start (Winter only. Slight parasitic draw)
- Napa Right Front Window Regulator.

Misc:
- Brand new OEM keys cut by dealership from VIN
- New Hatch Struts
- Rubber Cup Holder Insert
- Disassembled and repainted gauge needles (orange model paint)
- Emergency Brake rebuild
- Rear wiper motor lubricated with WD40 and brought back to life by hand-force.
- Disabled memory seat function and PDM swap from 96 ZJ with keyfobs
- Drivers-side heated seat repair

If anyone has questions about anything I've done, feel free to ask. I'd be more than happy to help

Pictures from when I got it:

http://i474.photobucket.com/albums/r...p/DSC_0214.jpg

http://i474.photobucket.com/albums/r...p/DSC_0242.jpg

http://i474.photobucket.com/albums/r...p/DSC_0271.jpg

http://i474.photobucket.com/albums/r...p/DSC_0256.jpg

http://i474.photobucket.com/albums/r...p/DSC_0252.jpg

http://i474.photobucket.com/albums/r...p/DSC_0244.jpg

http://i474.photobucket.com/albums/r...p/DSC_0221.jpg

Brand new spare; never mounted.
http://i474.photobucket.com/albums/r...p/DSC_0209.jpg

http://i474.photobucket.com/albums/r...p/DSC_0198.jpg

http://i474.photobucket.com/albums/r...p/DSC_0196.jpg

http://i474.photobucket.com/albums/r...p/DSC_0195.jpg

ThatJeepGuy 12-26-2010 12:08 AM

spoiled... What does the engine need to be "fixed up". I always liked those jeeps

pyrotyro 12-26-2010 12:15 AM

awesome present man!!

i bet that 5.9 is a BEAST! im jealous

csouers 12-26-2010 10:13 AM

Quote:

Originally Posted by ThatJeepGuy (Post 10679519)
spoiled... What does the engine need to be "fixed up". I always liked those jeeps

The engine is great, minus a noisy pulley (coming from the alternator area. My 5.2 does the same thing). Transmission is pretty wonky right now, but hopefully that's a simple fix. Overdrive needs rebuilt, but that's easy.

Quote:

Originally Posted by pyrotyro (Post 10679536)
awesome present man!!

i bet that 5.9 is a BEAST! im jealous

It is! Even at quarter throttle it's nuts. I'll definitely have to keep myself from "opening it up". :2thumbsup:

Lamont_24 12-26-2010 10:22 AM

I know what you mean about being suprised! My dad paid for a thousand dollars of my Highline fenders and then bought me a GPS and then gave me 185 bucks to whatever mod I want

pyrotyro 12-26-2010 05:27 PM

lucky! i got some clothes... had my fingers crossed for some new leaf springs... guess ill do that on my own dime. in like 3 years. college is expensive haha

65th 12-26-2010 06:53 PM

Damn, nice Jeep. I love the 5.9's

ajamison 12-26-2010 07:29 PM

congrats on the 5.9!! i had one and loved it!

jeepmanjc 12-26-2010 07:47 PM

that was quick haha, she is nice man...........lucky sob haha.keep me updated on the repairs, the trans issues worry me

csouers 12-29-2010 02:16 PM

Okay. Lets try posting a third time...

Got the stereos out of both Jeeps and the 5.9 is ready for the Alpine. Just gotta get the 5.2's interior torn apart to get the amp wiring out.

We're looking at the 5.9s transmission today. Hopefully we don't have to rebuild...

csouers 12-29-2010 08:42 PM

After continuous testing tonight, we have determined the 5.9 needs a PCM. GRRRRRR

The signal-in wire coming from the governor pressure sensor has an internal short to 5v supply in the PCM.

Evoluvin 12-30-2010 02:00 AM

damn dude. you are one lucky person!

01ClassicXJ 12-30-2010 06:49 AM

Since no one has asked this question why did you get a 5.9 for Christmas. When you were making a list did you just happen to jot down a 5.9 or was it a deal your dad found and couldn't pass up.

csouers 12-30-2010 10:53 AM

Quote:

Originally Posted by 01ClassicXJ (Post 10700892)
Since no one has asked this question why did you get a 5.9 for Christmas. When you were making a list did you just happen to jot down a 5.9 or was it a deal your dad found and couldn't pass up.

My dad found a deal. The only thing I got on my list was a camera backpack. I felt bad about getting a 5.9, but after I was told how much he paid, I didnt anymore. He'll make his money back for sure with the sale of the 96.

csouers 12-30-2010 05:41 PM

After continuous retesting and insuring that the tests were done correctly, it is for sure the PCM. Ordering one here in a minute with the same tuning as my broken one. (Fed emissions tuned to run on premium fuel)

I swapped the the 5.9 grille I bought a long time ago at the junkyard with the one off of the 5.9. The JY grille has some paint chips and a broken. I figured when I inevitably hit a deer, I'll still have a solid 5.9 grille to use.

Got all the custom wiring taken out of the 5.2 and ready to put it into the 5.9.

Also, the 5.9 has never had any of these parts changed: spark plugs, plug wires, rotor, distributor, or coil. Everything is original. The radiator even seems original, as it has the mopar sticker on the side of it.

This thing's going to run GREAT with all the new parts we're putting in it. Very excited to finally drive it!


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