Ken's Big Red XJ - JeepForum.com

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post #1 of 27 Old 02-08-2016, 11:49 PM Thread Starter
Ken3783
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Ken's Big Red XJ

Figured I'd start a build to document the "new to me" '98 Cherokee I just picked up. I got it for FREE because the previous owner is transferring off the island and it's too expensive for him to transport. Plus, there's a few things that need to be looked at and replaced that he just didn't have the time for.

The engine isn't firing on all cylinders at current and has a dead battery. There's a loud "clicking" noise coming from the front axle, mostly from the right side. Has weak brakes, new steering components, and a few other things. From what I can see of the lift it's a BDS 6.5 " lift that's in really good condition still. No rot found anywhere but there is a leak coming into the interior somewhere I have to track down and stop.

This project is mostly for my son. Well be working on this together every step of the way so he can see how to fix and maintain a car. I wanted something he'd have to work on and bleed a little for. He doesn't know he's building his own car though. I'm really excited to build this with him.





Sitting next to the YJ:







'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #2 of 27 Old 02-09-2016, 04:57 AM
clean4drxj
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Sounds like a great plan.


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post #3 of 27 Old 02-09-2016, 10:53 PM Thread Starter
Ken3783
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Quote:
Originally Posted by clean4drxj View Post
Sounds like a great plan.
Thanks.

The spark plugs are definitely an issue but not the issue. Checked wires and distributor cap, but they looked brand new almost. I'm fairly sure the coolant overfill hose went through the fan as only 1/3 of the hose is left. The battery is being reconditioned. The list only grows the more I look at things but I'm in no rush. The exhaust manifold is cracked, but I expected that. I did not, however, expect to see the muffler and driveshaft in a competition for who can wear through who faster. The boy had fun pulling all the parts off to inspect them and reinstall them. More tomorrow.




After I pried the 2 fighters apart:


'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #4 of 27 Old 02-10-2016, 04:35 AM
clean4drxj
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Might be time to look into some browndog mounts, the stock allow to much movement when pushing larger tired ect.


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post #5 of 27 Old 02-11-2016, 10:23 PM Thread Starter
Ken3783
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Still no go on starting. The distributor cap was toast, so replaced the cap and rotor. Changed out the spark plugs because a couples of those were junk. Checked the fuel rail, which is working fine and primed as well as the fuel pump. Not sure if the ignition coil is supposed to be putting out consistent voltage during the starting sequence or not, but it's not it's all over the place. I might have to pick up a crankshaft position sensor too but I'm not there yet. It's cranking but not even attempting to turn over. I'll try some more troubleshooting tomorrow.

'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #6 of 27 Old 02-11-2016, 11:59 PM
MOBBiN
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Score on the free jeep! Following from south central Alaska

2001 Silverstone Metallic Classic XJ
Build Thread
April 2014 & 2015 COTM
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post #7 of 27 Old 02-12-2016, 01:09 AM Thread Starter
Ken3783
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Quote:
Originally Posted by MOBBiN View Post
Score on the free jeep! Following from south central Alaska
Thanks! Right place, right time. He was going to toss it in the dump if I hadn't some along.....would've been very sad considering it's definitely fixable. Plus its just fun to have a project again as my YJ is kind of at a stand still til I can get the space to dig deep into it and do my diesel swap etc, etc. The boy is really enjoying working on it every night and learning new stuff.

Also forgot to mention that when I got the new distributor cap and rotor at NAPA, they gave me some new brake pads for FREE. Someone had come in before I got there, ranting about how he bought these pads on amazon and they weren't the right ones. He gave them to the NAPA guys to give away. Well they just happen to fit a 98 XJ SCORE!

The wife and I were contemplating retiring to South Central Alaska when my 20 years is up and I can retire, outskirts of Anchorage somewhere. I heard Eagle River is really nice. We'll see how it all plays out. We've never been up there but we know, after everywhere we've been, we don't want to be anywhere else but Alaska.

'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #8 of 27 Old 02-13-2016, 01:52 PM Thread Starter
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Still no starting. 10vdc coming out of the coil but nothing measured coming out of the distributor cap that I saw. Plug wire resistances look good. New Cap, new rotor, new plugs. The power going into the CPS seems right, 5v constant on one, with a good ground on the middle and the square wave on the other. Fuel is primed and I can smell the fuel during cranking. Checked fuses and swapped out the ASD relay with a spare and no real corrosion in the PDC. I verified the plugs on the cap were in the correct order and the cap is installed correcting. The rotor was also verified to be turning during cranking. The cranking does seem a little slow but that could also be that's normal but I am unfamiliar as its new to me. I tried to ground the plugs too with a spare and no spark. So knowing that I think that's what I'm focused on. It still could be the coil, as 10v with no amps wouldn't have the juice to make it through the plug wires. Still more troubleshooting to go and of course the NAPA here has nothing I need in stock.

'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #9 of 27 Old 02-13-2016, 10:49 PM Thread Starter
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So I think I finally figured the starting issue out, several forum searches and websites later. Lots of good tips out there, this one in particular: http://troubleshootmyvehicle.com/jee...gnition-coil-1. Everything led me to the ignition coil being bad, even though the primary and secondary resistances read good. So new coil on the way.

Since I'm waiting on parts I figured I'd move on to the next big issue, aka the "clicking" on the axle. I'd call it banging, personally. Either way, I jacked it up and started my usual checks with the components. The left side was nice, no issue really noted. I got to the right side and accidentally bumped the tire sitting down and the whole thing shifted sideways. That hub was toast!!!! I could move the whole thing sideways like the lugnuts were loose. Got it all apart and replaced the hubs fairly quickly. I did have to break out the blowtorch for the 36mm nut holding the axle shaft assembly to the hub. Fastest hub change I've personally ever had though. I have a video, but not sure how to post that yet.



Good thing I got those free brake pads from Napa because the ones on there were worn out and cracked though, most likely since the brake pads were taking all the strain of keeping the tire upright.


'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #10 of 27 Old 02-14-2016, 01:54 PM
lovett86
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Nice project

its a rusty one

http://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #11 of 27 Old 02-15-2016, 11:28 AM Thread Starter
Ken3783
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Got the left hub replaced even faster than the right side. I had the boy do the all of the work this time. He did quite well. There was a casualty of war today though, my clamp, god rest it's soul, didn't make it through the day. It was snapped in half by the callus and heinous acts of the right brake caliper. I went to put the new brake pads on and the caliper would not budge. Naturally, I opened the brake line and attempted to use a clamp to open the caliper piston further and snap went the clamp. The caliper is completely seized in place. This obviously explains part of the sketchy braking on the way to the house while we flat towing it. New parts on the way....







Also removed the rusted and busted nerf bars. No point in those things. Looks a lot better now.


'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #12 of 27 Old 02-16-2016, 06:36 PM Thread Starter
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So I was looking at other XJ's with a 6.5" lift and mine seemed much bigger. Did some looking and measuring and it appears that while a 6.5" kit was put on so was a 2.5" spacer lift, its actually at 9" of lift not including the tires. I guess I just skipped over seeing the spacers on there. The rear shackles are some homemade looking garbage so those are coming off as soon as I figure out how much of a shackle lift was added..... This thing is coming back down to a 6.5" lift. There is also not a SYE kit on here; still the slip yoke...not good. So SYE and new rear DS to come. I'm sure this thing has got to have driveline vibes but was never driven fast enough to know or care. Definitely going to take some time to straighten all this out. It'll be good experience for the boy though. Time to gut the interior and clean it up, as well as measure those Home Depot shackles.

'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #13 of 27 Old 02-17-2016, 09:45 AM
clean4drxj
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Yeah there's really no need for a lift that high. It's still good to have a longer shackle then stock so you can utilize the leafs in the back and get a better ride.


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post #14 of 27 Old 02-19-2016, 07:40 PM Thread Starter
Ken3783
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So I was pulling the carpet up to get all the water out of the inside and clean it all up and found the water coming from somewhere around the heater box. I also found that the forward floor pans on both sides require replacement. The boy is gonna get the total package in this learning process. He'll definitely understand why we take care of things sooner rather than later and was corrosion prevention is so important.


'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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post #15 of 27 Old 02-19-2016, 11:43 PM Thread Starter
Ken3783
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Got my calipers, wheel cylinders, and grill in yesterday. Somehow I ordered a door check instead of a hinge for the drivers door, so I'll have to reorder the right part. The ignition coil and liftgate supports come in tomorrow, so we'll see if it fires up. Ordered the floor pans tonight. I had to ebay them since shipping up here was $258 for $140 worth of parts from everywhere else.....that wasn't going to work for me. Ebay...$50 in shipping.....SOLD! Tomorrow will be a busy day dropping all these parts in. Hopefully I have time this weekend to also drop the spacer lift out and drop the rear shackles a couple holes to establish the correct size of shackle I need to order. I applaud homemade stuff if it's done correctly, but these absolutely weren't.

'95 Wrangler YJ: http://www.jeepforum.com/forum/f22/m...rship-1481851/
'98 Cherokee XJ: http://www.jeepforum.com/forum/f22/k...41/index2.html
'07 Grand Cherokee WK ("No Mods"-The Wife)
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