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Unread 06-07-2013, 08:43 PM   #1
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
New Life

I bought this Jeep back in 2008, as it sits here in this picture.



I bought off a kid that knew nothing about it for pretty cheap. Had a 3.5 inch lift, 31 inch BFG A/Ts, brush guard, tail light guards, some no name cat-back exhaust and came with a roof rack and factory rails.

For a while I didn't really do much to it. Just added a few things here and there. It looked like this



[IMG][/IMG]

I added a CB and antenna, added the roof rack on, added KC daylighters on the front, added front recovery and put a sterio speakers sub and amp in. The problem at this point was no trailer hitch and the person who put the lift in cheaped out and used lift blocks in the rear. So after driving it like that for a few years I finally put some work into it.



Those are rusty's 3.5 inch springs, a trailer hitch and rock rails.

First thing to go on was the hitch.



you can also see the lift blocks that were used.

next was the leaf springs







And finally with them installed. Much better. Rode a lot nicer, and worked way better than the blocks ever did.





At that time they gave me 4 inches of actual lift height. Im not sure what they are now.

After that I there were just a few odds and ends that got installed. Which include extended rear brake lines and new headlights.

Then I did this



That was the second time doing that, just so you know.

So I found a new hatch and installed it





was the same color and everything

Soon after this I had to change the shocks out. So I got bilstein 5100s





Then lastly, in this life, I installed an IRO hack and tap. I don't have a picture of that though.

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Unread 06-07-2013, 08:49 PM   #2
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Then started a new life. Nothing happened with this Jeep for a couple years. I drove back and forth to college and work, did some light wheeling here or there. Now that I am graduated college it's time to put more money and time into this Jeep. My ultimate goal is to run 37s on about 5.5 inches of lift. Plus cage work, bumpers, winch, lockers etc.

Here is one issue



My rockers are also 100% non existent at this point. So that needs fixing.

I came across a set of wagoneer dana 44s. I decided I couldn't pass em up and figured i'd go take a look at em. I ended up getting them for 175 dollars, they need work but they were cheap.



Decided to start with the rear



Most of the gear oil came out through the pinion seal. I used a needle scaler and took all of the loose ****.





pulled the diff cover to see what was going on in there



It's got 2.72:1 ratio



The drums needed to be cut off. One was already broken and the other ended up breaking trying to free it up. So cutting em wasn't a big deal





There was this track bar looking bracket thing that we cut off.



And that was it for now. Next sept is cleaning it up real good throughing some primer on it and redoing the brakes, mount new shock mounts, regearing, seals, paint and it'll get mounted.



Also came with a set of 4:10 gears




I then went to a junk yard and cut this piece out to patch up the hole



Left a nice hole in the jeep at the yard



wire wheeled the axle down



throw on a coat of primer



Most recently I took out all the **** inside so I could replace what needed to be replace and such







Basically I made a big mess. Again




and here it sits until I get the rest of the parts together. I have all the stuff to do the brakes, just need seals and some bearings.


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Unread 06-07-2013, 09:15 PM   #3
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
I have collected all of the parts to put it back together at this point. The only things missing are the inner seals, which I'll have to go down and get tomorrow (June 8th 2013) and the rims, I'll grab a pick of those tomorrow.











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Unread 06-07-2013, 09:18 PM   #4
JeepNE
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1999 TJ Wrangler 
 
Join Date: Feb 2009
Location: Western Mass
Posts: 299
Looking good, nice job so far. Can't wait to see it progress
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Unread 06-08-2013, 09:14 AM   #5
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
I have a question about the rear inner seals on this axle. I went this morning to get it from auto zone and I went to see if was and it's not. So I looked on the suto zone website and it is in fact sold as the inner seal for this axle, but it's not the right size. I've done a lot of looking around for where to find the correct rear inner seal to no avail. Any one have any ideas?
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Unread 06-12-2013, 01:24 PM   #6
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Here are those rims I got. They are currently chrome, but im gonna paint them black.



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Unread 06-20-2013, 08:20 PM   #7
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Well today was spent working on this pile.

I put my shafts in the downstairs fridge on the coldest setting overnight to hopefully make pressing on the wheel bearing easier.



It was about 30 degrees in there this morning.

This is one side down. Used a long pipe and a big sledge hammer.



This is the setup. The axle retaining plate goes on first, then the seal, bearing and finally the bearing retainer. The pipe I had fit on the retainer perfectly. Then it a matter of swinging the hammer.





Then the rest of my day was spent cutting out what was left of my rocker panels.







I cleaned out the insides of them best I cold and put down a nice coat of primer to stop it from rotting away further.





There are some decent holes behind those panels, so that needs to be fixed. But my plans here are to build in some rock sliders in place of normal rocker panels. Gonna make a trip down to a local metal shop for supplies.

Mess time





Bucket o'rot

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Unread 07-04-2013, 11:09 PM   #8
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213


Cut out a patch



Not that bad for a couple amateurs



Also found a small hole under the trim piece that goes in the very back.



Then I just put a nice coat of primer over em and seal up the underside. I am not going to put the carpet back, I am going to use a herculiner or raptor liner to coat the rear section with. Eventually I'll do the entire floor.

Im taking up a nice corner of the garage now.



Metal for the rocker panels

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Unread 07-05-2013, 01:22 AM   #9
karlo
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Join Date: Jan 2009
Location: Florida
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Great job! Looking forward to see more updates.
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Unread 07-08-2013, 08:34 PM   #10
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Laid down some herculiner in the back





In between coats I put the new pinion bearing on. Throw the pinion in the freezer and used a pipe that fit on the inner race and pounded it on with a big sledge



I also put this in.





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Unread 07-11-2013, 01:14 PM   #11
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Got the interior back together.



Had to get a little creative to re tighten this torque bolt. Torques bits don't like impact wrenches or three foot pipes



Now the fun stuff

Set up bearings



After working on em for 6 or 7 hours I got them set up within spec





Then threw the axle shafts in

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Unread 07-11-2013, 03:48 PM   #12
MachinistMade
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1992 XJ Cherokee 
 
Join Date: Oct 2008
Location: , MN
Posts: 94
Great build so far!
Also nice score on the dana 44's for $175!
hard to find where i am at, and even if i could no way am i getting them for that price!
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MY BUILD THREAD:
http://www.jeepforum.com/forum/f22/machinistmades-grenade-xj-build-1353460/
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Unread 07-11-2013, 07:53 PM   #13
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Yeah I got really lucky with those.
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Unread 07-19-2013, 04:28 PM   #14
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
The rear axle is all together besides sealing up the diff cover and welding on the shock mounts.









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Unread 07-24-2013, 09:12 PM   #15
KINGJB
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1999 XJ Cherokee 
 
Join Date: Oct 2008
Location: Massachusetts
Posts: 1,213
Started tearing into the front axle













And have all the brackets cut off. Gonna clean it up and throw a coat of primer on it to match the rear.

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