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Introducing MONSTALINER™ UV Permanent DIY Roll On Bed Line~Artec JK 1 TON SWAP~Advance Adapters SYE Kits

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Unread 12-25-2010, 10:56 PM   #1
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
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:















Brand new spare; never mounted.








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1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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Unread 12-25-2010, 11:08 PM   #2
ThatJeepGuy
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1993 YJ Wrangler 
 
Join Date: Feb 2010
Location: Delta, Peach Bottom
Posts: 265
spoiled... What does the engine need to be "fixed up". I always liked those jeeps
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Unread 12-25-2010, 11:15 PM   #3
pyrotyro
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1998 XJ Cherokee 
 
Join Date: Jan 2009
Location: Crawlorado
Posts: 1,081
awesome present man!!

i bet that 5.9 is a BEAST! im jealous
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Unread 12-26-2010, 09:13 AM   #4
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
Quote:
Originally Posted by ThatJeepGuy View Post
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 View Post
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".
__________________
1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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Unread 12-26-2010, 09:22 AM   #5
Lamont_24
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1999 TJ Wrangler 
 
Join Date: Apr 2010
Location: Bremen, IN, Indiana
Posts: 737
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
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[COLOR="Indigo"]Purple Jeep Club member #13[/COLOR]
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Unread 12-26-2010, 04:27 PM   #6
pyrotyro
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1998 XJ Cherokee 
 
Join Date: Jan 2009
Location: Crawlorado
Posts: 1,081
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
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Unread 12-26-2010, 05:53 PM   #7
65th
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2006 TJ Wrangler 
 
Join Date: Nov 2010
Location: Northville, Michigan
Posts: 84
Damn, nice Jeep. I love the 5.9's
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2006 Jeep Wrangler- 65th Anniversary Edition- Jeep Green Metallic- 2 inch Budget Boost- 32" BFG All-Terrains - PIAA Fogs
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Unread 12-26-2010, 06:29 PM   #8
ajamison
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1991 MJ Comanche 
 
Join Date: Feb 2009
Location: York PA
Posts: 1,712
congrats on the 5.9!! i had one and loved it!
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Unread 12-26-2010, 06:47 PM   #9
jeepmanjc
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1998 XJ Cherokee 
 
Join Date: Dec 2009
Location: currituck, nc
Posts: 298
that was quick haha, she is nice man...........lucky sob haha.keep me updated on the repairs, the trans issues worry me
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'98 xj sport cherry bomb 205,000 miles, 5ft whip, blacked out lights
http://www.jeepforum.com/forum/f6/support-jeepforum-equipment-drive-963790/
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Unread 12-29-2010, 01:16 PM   #10
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
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...
__________________
1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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Unread 12-29-2010, 07:42 PM   #11
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
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.
__________________
1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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Unread 12-30-2010, 01:00 AM   #12
Evoluvin
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Join Date: Jul 2009
Location: Baltimore, MD
Posts: 198
damn dude. you are one lucky person!
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Looking to buy a TJ in the Mid-Atlantic area ASAP!!!! Please message me with what you have.

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Unread 12-30-2010, 05:49 AM   #13
01ClassicXJ
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2001 XJ Cherokee 
 
Join Date: Nov 2008
Location: Warwick/Middletown NY
Posts: 1,286
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.
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Unread 12-30-2010, 09:53 AM   #14
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
Quote:
Originally Posted by 01ClassicXJ View Post
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.
__________________
1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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Unread 12-30-2010, 04:41 PM   #15
csouers
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1999 XJ Cherokee 
 
Join Date: Feb 2008
Location: Bloomington, Indiana
Posts: 2,027
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!
__________________
1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

My Photography
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