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Unread 08-08-2011, 09:55 PM   #1
overlandchris
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2004 WJ 
 
Join Date: May 2009
Location: Quincy MA, Massachusetts
Posts: 324
96 XJ "shamrock" build/02 TJ build

Well i am one week into my 96 X jproject. It is a 96 XJ country with automatic, I6 and a standard amount of rust. I have accomplished a fair amount but its nothing compared to what is ahead of me.
My first week was spent getting the engine to turn over and run with out leaking, stalling, making unreasonable noises at me, spraying me in the face, or other wise functioning improperly. Today i was successful, Hear is the run down of what it took to get it going,
Water pump, Thermostat, antifreeze, heater control valve, oil pressure switch, plenty of RTV, new oil, oil filter, electric radiator fan, and a fuel pump relay. The water pump was toast, previous owner filled the system with just WATER. Any way after replacing all that and doing a fluids change now she runs not great but well enough to take it out for a 10 minuet spin. The engine hadn't been started in a month or so based on how its running. AS for now the main goal is to get it road worthy
list for that is
replace floors
rehang exhaust,
Have the leaf springs reconditioned
work out all the engine problems
and reassemble the interior
As for the build up the list is as follows
4 inch suspension kit
Tires
Build a piaa light bar of some kind
T-case swap
Stroker kit(in the far future)
Home made bumpers front and rear
As for now i have some questions and some issues that i could really use some help with.
First is my gauge cluster seems to have died on me. Tach and speedometer both function as does the volt meter but my gas gauge, oil pressure gauge, and coolant temperature gauge all don't function any more and the illumination has stopped working. Any ideas on this? Also I want to swap the command-track transfer case out for the Select track transfer case. How easy is it and is it worth it?

image.jpeg   image-1.jpeg   photo-3.jpg  
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-16-2011, 09:49 AM   #2
overlandchris
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Join Date: May 2009
Location: Quincy MA, Massachusetts
Posts: 324
Well it's come along a bit since I started the thread, installed fog lights, wired up my light bar harness, got my rear breaks working properly again, fix all my electrical problems. Now the jeep is giving me a hell of a time. I can't get my engine running properly. It is having cooling issues again. It's not flowing properly and the temp sensor isn't working either, there is a crack in thermostat housing that's new. It's knocking badly and I am not sure if this engine is worth salvaging any more. Any opinions on this?
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-16-2011, 10:19 AM   #3
FleshEater
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Well...is this a project or is this a hurry up and build it? If it's a project and it's not taking up too much room and you have time and want an experience then YES it's worth keeping. If you want a quick fix and run then no. Good thing about the motor going is that you can put a stroker in sooner rather than later. As for the other parts...start searching the forums. There are XJ part outs EVERYWHERE that you should be able to save money on the old girl. Got a lot of nice sheet metal left in those floors as well. Get a list of proper functioning items first then worry about your build...give yourself a year to get it complete and if it's not done by then, then throw it away. Look at the theBlackSmith's build...he's going on a year of headaches and I think I'm on 5 or 6 months and mine still hasn't seen the road.
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Unread 09-16-2011, 02:11 PM   #4
overlandchris
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Well said, most parts I get off eBay or I use my e coupon on advance to get the parts I need new. It's definitely not a hurried build I don't intend to lift it till the late spring or summer of 2012. My biggest problem now is the engine. I either rebuild it over the winter or get a reman, the cost on the machine work would cost just as much as a reman and that's before she gets new guts.
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-17-2011, 12:55 PM   #5
FleshEater
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Man if you were closer to me we have a machine shop that will rebuild racing motors for under $2,000; stroking a 4.0 would be even cheaper than that.

If come out of this XJ with a super built machine for less than $6,000 then you're doing awesome.
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Unread 09-19-2011, 05:42 PM   #6
overlandchris
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One hanger fixed one to go. Now there are no more exhaust noises. The hanger on my crosmember has been cut, so I either have to replace it or weld the two pieces back together. I changed the spark plugs about 3 weeks ago and I used the Boch +4 plugs because they were on sale. Is it possible that these plugs boils be causing my knocking problem?
image-2289166333.jpg   image-538888096.jpg   image-339298002.jpg  
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-19-2011, 07:10 PM   #7
FleshEater
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Probably not...they would only cause slow starts or lack of ignition/miss.

If this is able to drive a little ways you could try to get rid of the "knock" with the ATF trick...however, I believe that's for a lifter. Not sure if you have pinpointed the source of your motor noise or not.
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Unread 09-19-2011, 08:16 PM   #8
overlandchris
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I have had 4 people listen to the engine and tell me what they think, they all said that they think that the damaged exhaust manifold is causing air to be sucked in through it and that is causing my problem. Just out of curiosity what is the ATF trick?
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-19-2011, 08:32 PM   #9
FleshEater
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I believe it's for a lifter tick; you run ATF in the motor for 100 miles and then change oil, run it and change oil again. Hell if it's a manifold then upgrade and get a header!
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Unread 09-27-2011, 08:55 PM   #10
overlandchris
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Location: Quincy MA, Massachusetts
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Well I did a test to see how I like the tan stuff black, and I think it looks way better. I am also going to re do the country logo and stripes over by hand in orange. But I have to start it right to and paint it properly this was just a test.
image-3164677210.jpg   image-3791737421.jpg   image-3731624069.jpg  
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-28-2011, 10:09 AM   #11
FleshEater
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Looks a lot better in shiny black.

How are those floors coming?
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Gone but not forgotten; 2005 LJ *SOLD* 1987 XJ *SOLD* 2002 WJ *SOLD* 1995 ZJ *SOLD*
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Unread 09-28-2011, 02:32 PM   #12
overlandchris
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Location: Quincy MA, Massachusetts
Posts: 324
Haven't started yet, I am going to use quadratec's stamped floor pans, for the purposes of time and tools. I will have to take it to my buddy's place to do the work because I am a crappy welder and I dont have the metal work tools that we need. Right now the main goal is to get the engine up and running right. New manifold is going in I'm a couple weeks so hopefully that will end my engine troubles.
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-28-2011, 02:47 PM   #13
FleshEater
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Dude if this is going to be a trail rig and a beat the piss out of it having fun then just do what I did. It's just as easy and a hell of a lot cheaper. Get some scrap metal as thick or thicker than road signs, hammer to fit and drill it down.

It's all in my build thread.

If you start nit picking this vehicle apart you're going to be in for some deep money. I'm at $2348 and that's just getting it 100% safe and road legal and comfortable.
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Unread 09-28-2011, 03:11 PM   #14
overlandchris
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Location: Quincy MA, Massachusetts
Posts: 324
She is going to be a road trip jeep also, and I want to take it to the mountains in the winter, and I want to travel the country to off roading havens. I need her to be good and sturdy.
__________________
4.7 V8 H.O. The Chevy 302 of Jeep Engines. Roar...

2004 Grand Cherokee Overland, Midnight Blue Pearl.
Rusty's 2" Budget boost, It Goes fast
Project "Shamrock": 96 Cherokee country, black, I6 HO, ZJ 242, 4.5 Rustys, 33" Mud terrains
My build: [url]http://www.jeepforum.com/forum/f22/96-xj-shamrock-build-1250478/[/url]
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Unread 09-29-2011, 06:55 AM   #15
FleshEater
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Location: Hell, PA
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Oh boy...empty yer pockets!
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Gone but not forgotten; 2005 LJ *SOLD* 1987 XJ *SOLD* 2002 WJ *SOLD* 1995 ZJ *SOLD*
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