96XJ Forest-Cruiser buid - JeepForum.com

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post #1 of 45 Old 01-24-2016, 09:37 AM Thread Starter
kzim93jpz
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96XJ Forest-Cruiser buid

I am finally putting my build up on here to document my progress and swap ideas and advice. I first got into jeeps and fourwheeling with a 00 XJ I wrecked. The goal is to turn it into a reliable weekend xplorer and camping vehicle. I picked this one up on craigslist for a 1,000$. It didn't run and has a bit of rust I am trying to fix. The no start issue happened to just be a blown fuse. So on to the Jeep its a 96 with a 4.0 HO with 211,000 miles an AX15 transmission NP231 D30 and D35 axles

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post #2 of 45 Old 01-24-2016, 10:08 AM Thread Starter
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Here is pic of it in stock form. Its gonna take me awhile to catch up to my current progress.
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post #3 of 45 Old 01-24-2016, 10:56 AM Thread Starter
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The first thing I did was gut the interior. Headliner was sagging so took that out and the carpet so I could fix the floor. Both rear corners were rusted thru and the front passenger side floor pan is bad here are a couple pics of fixing up the rear and herculining the inside. If you wanna see anything special let me know I have alot of pics.. I won't be posting them all
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post #4 of 45 Old 01-24-2016, 11:18 AM Thread Starter
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After reading others builds on the forums for months. I decided to go with a 4.5in lift and 33s. I went with rubicon express short arm 4.5in with monotube shocks which to my surprise are actually bisteins. I also swapped out the d35 for a Chrysler 8.25 I got off craigslist...not sure of the gear ratio but ill be doing a regear soon enough. I also wire wheeled the underside and primered and painted it with rustoleum black.
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post #5 of 45 Old 01-24-2016, 12:23 PM Thread Starter
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Putting the lift kit on wasn't overly difficult. Only two of the upper rear shock bolts broke off so I drilled and tapped them. Drilling out the upper trackbar mount was tough. The lift only had ubolts for the 35 so I had too order some others for the chry. The rear leaf springs were shot a couple leaves were broke in half. We aligned it with a tape measure for the time being. I also cut the front bumper and the fenders really opens it up nice
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post #6 of 45 Old 01-24-2016, 12:33 PM Thread Starter
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It looks really goofy with the little donuts under it..I've been contemplating whether to go with 31s or 33s and between the BFG km2 or mickey thompson mtz. I was also checking around on craigslist. The rear of the xj sits about 2in higher than the front and the shackle angle is terrible gonna deal with that later on
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post #7 of 45 Old 01-24-2016, 12:42 PM Thread Starter
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Ordered some goodies from summit. New distributor cap,wires and plugs a felpro valve cover gasget and the real winner... advanced adapters np231 sye. Everything went together smoothly now I need to order a driveshaft
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post #8 of 45 Old 01-24-2016, 12:54 PM Thread Starter
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I went to the Jeep Show at York Fairgrounds what a blast except it rained in the morning...the first show I've been to I bought a front bumper, all the brackets,bolts and steering box spacer for 250$ from Creepy Fabrication. Can't beat that...it is a solid bumper and I had been eyeing DIY bumpers from JCR and Dirtbound Offroad previously
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post #9 of 45 Old 01-24-2016, 01:06 PM Thread Starter
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What do we have here???? I ordered gloss black steel procomp wheels with 3.75in backspacing in 15" and 33x10.5r15 BFG KM2s from 4wheel auto parts...they came mounted and balanced .. I went with the narrower tire in hopes it may help fuel mileage also sold the old wheels and tires on craigslist and recouped 200$ for more Jeep parts btw I weighed the tires to see how much weight I was adding. The new wheels and tires added bout 100lbs total over the stock ones and weighed around 75lbs ea.
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post #10 of 45 Old 01-24-2016, 01:20 PM Thread Starter
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I ordered a double carden driveshaft off ebay..got my bumper painted and installed it..and put the tires on.. I had to trim the inside of my fenders alittle..I would like to put bushwhacker or napier flat flares on someday?
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post #11 of 45 Old 01-24-2016, 01:48 PM Thread Starter
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After doing alot of research I decided to order gears for the rear and since ECGS was running a sale. The front will wait for alittle bit...ordered a 4.56 motive gear r&p which they didnt have in stock so I got upgraded for the same price to a nitro set!! Also got a master install kit, wheel bearings a magnetic base and dial indicater. And while your doing all that may as well put a locker in huh so I also ordered a detroit truetrac. .I know a selectable is the way to go but so many $$$
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post #12 of 45 Old 01-24-2016, 02:05 PM Thread Starter
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Awhile ago I ordered a passenger floor pan from z&m jeeps. I cut out the floor, now I just need to finish welding it in. Btw I hate rust; but being's i was looking for a 5spd. manual for cheap i couldn't be picky. In hoping to have it on the road by spring. Till then I have to keep busy.
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post #13 of 45 Old 01-24-2016, 02:14 PM Thread Starter
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I also did a zj tierod swap and new rod ends.It is a good bit beefier, aught to do the trick for now. And finally to fix the shackle angle and level the heep. Ordered the no lift shackle relocaters from H.D. Engineering; these things are massive
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post #14 of 45 Old 01-24-2016, 02:21 PM Thread Starter
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Got the shackle relocaters finished this weekend...seems like it definitely improved the flex..I need to get more black paint to finish them up..cant wait to take it around the block
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post #15 of 45 Old 01-24-2016, 02:31 PM Thread Starter
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Now things to be done yet!!!
Finish the floor pan & herculine it all, put the interior together somewhat
Setup the gears and locker, put Speedo gear in
Drop it off at the shop for exhaust & alignment
Do some engine maintenance and get it inspected once
Keep posted because there is a never ending parts list..need to get it on the road so we can start the fun
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