Jeep Enthusiast Forums banner

Kevin108's 2000 XJ Build

249K views 648 replies 93 participants last post by  soapy 
#1 · (Edited)
Kevin108's 2000 XJ Build, "Outsider"



I have really enjoyed reading others' build threads here. I didn't think I'd ever write one since I planned to leave my XJ more or less stock, but I keep doing things to it and my original plans are continually altered. With that in mind and a cold Yuengling at hand, I guess I'll start telling my story.

I started thinking about a new daily driver in May of 2009. I'd sold my 05 Corolla in December the previous year and after almost 6 months back in my 87 Silverado, I was realizing that I needed something more practical as a daily driver though I wanted a something somewhat capable as well.

I really didn't have any clue what I might wind up with, so I started a post at GlockTalk. Those guys know everything!

I have an 87 Silverado on 35s that started life as an offroad rig and wound up as a work truck for side jobs and a tow rig for hauling the ATVs. It's also been a daily driver for the last 6 months. As gas continues to creep back towards $3 a gallon, it's around-town 8 mpg has me eyeing something smaller for regular driving duties. I had an 05 Corolla that was a great car, just not at all what I needed for the places I go and the things I like to do.

My shopping specs:

$10,000 or less
Must be 4x4
At least 15 mpg
Auto tranny preferred substantially but a manual is acceptable on a sweet deal

My current train of thought is a small 4-door SUV like a Liberty, RAV4 or CRV. I don't know anything about them though, if some years were better than others, etc. Any suggestions?
The 8th reply suggested an XJ. I eyed some TJs as well but I quickly realized that they were priced about 2½ times more than an XJ of the same year even though they had essentially the same drive train and other components!

The XJ was it. Good engine, solid front axle, able to tow the ATVs, available with 4 doors, and a fantastic platform should I ever decide to build another offroad rig. Then I couldn't find one to save my life! There was nothing out there! Dealers had everything and wanted $2,000 more than their junk was worth.

Finally, after giving up and 2 months, I happened to find a CraigsList add for my XJ. After a couple of test drives, inspecting every square inch of it and a weekend of waiting on the bank to do their thing, I got to bring home my new XJ.



After a couple of days, the AC started acting up and after a couple of weeks or so, the blower quit completely. I was really aggravated that these problems hadn't surfaced during the test drives but such is life with a 10-year-old rig. I rode around for days with a multimeter in the passenger seat and after pulling the blower out all together, I found the problem to be the plug going into the blower motor resistor.

At some point the blower had gone bad overheating the resistor. Both of those had been replaced. When the resistor overheated, it ruined the plug as well but that didn't stop a previous owner, which was not the guy I bought it from, from faking a fix.



I'm yet to find the proper plug but the insulated spade connectors I added that fit tightly on the resistor contacts are working great.

Around the same time, I installed a Curt Class III receiver on the rear along with a wiring harness for the trailer. The hitch installation was easy save for one bolt on the heat shield between the muffler and the gas tank. I managed to strip the guts of a cheap ratchet and even with Snap-On stuff, a 2' breaker bar and an impact wrench, it was still hard to get that bolt out. The wiring made up for the hitch's difficulty by being plug and play.



After I got the hitch installed, I made a test run towing my ATVs at highway speeds on the interstate on a 105° day. I got my transmission temps up to 191° so I started shopping transmission coolers. I bought a 25,000 lb-rated unit and set it up in front of the mechanical fan so that it always had some amount of air moving over it.


Mounting location


I sleeved the upper hose. I felt that wind could make it make contact with the condenser. I also split a section of hose and wrapped around the opening of the hole to protect the active hoses.


The view from underneath


Where the hoses meet the hard lines

Around the same time, I mounted a 3-D-cell Mag-Lite to the passenger side A-pillar.



A week or so after that I painted the trim.





I gave it a good wash last week and painted the wiper arms.

 
See less See more
12
#333 ·
Okay, getting back to this heap. Tomorrow I'm ordering an adjustable track bar. I was going for the Rough Country because it was cheaper until I realized the IRO is solid stock for $10 more. Also, as soon as Treadwright has them in stock, I'll be ordering two more of their MT/R clones.
 
#334 ·
I'm about to start the installation of my Iron Rock Offroad adjustable track bar. Everything came boxed up tight and wrapped in foam and plastic. I caught their Christmas special and it shipped free via FedEx. Last night I got everything unboxed and opened up. I had a few minutes of prep to do as a while back my track bar had come loose and wallowed out the mount. To fix it, I drilled it out to 1/2" and replaced the bolt. To make the new components work, I had to drill out the bushing sleeve to 1/2". That took a minute or so in a vise with some sharp drill bits. I'll update with some more pics when I'm done.

(Yes, I know the bar is upside down! lol I just wanted it stable for the picture.)
 
#335 ·


I got sidetracked on the track bar. Ended up cleaning for two days. I did a side job last month for a guy where I replaced the handrail around his porch. I went to take a sample spindle to match the paint color and ended up ripping the whole porch to pieces and bringing home in my XJ. I had fully intended to use my truck for this but I just went with it.

In the end, I had rotten wood crumbs and latex paint chips all over the interior, not to mention sawdust, tools and scraps. I started off emptying everything out.


In the process, I found my stock jack and thought I'd see if it still worked with 31s. Nope. Bye!


That left a bracket under the seat I didn't need anymore. Bye!


Then I had a hole in the carpet and padding I didn't need. Seemed like a good home for an Altoids tin full of spare fuses.


Epic times were had with a ShopVac and I organized my under-seat storage in a more logical fashion.


Then it was time to repack the pile and discover the orange box is so heavy because at some point I added a spare starter to my kit.


Cleaning the back out was a relatively quick affair compared to the front because of the Isuzu mat I dug out of the garbage and trimmed to fit. :shhh:


Organized, secured and rolling again.
 
#336 ·
I finally got around to installing my Iron Rock Offroad track bar tonight. Thought I'd share some notes.

This is the mangled bushing from my stock track bar. Note how thin the walls of the sleeve are. The bolt had wallowed out in the mount twice so I'd wound up drilling everything out to ½" to take up the slack.
(Image forthcoming.)

Because of this, I had to start off with a modification to the IRO part. It too is now drilled out to ½" but you can see they give you a much thicker-walled sleeve to work with.


This is the new track bar fully assembled. Yes, the two ends are 180° out. No, that's not how it was mounted.


This is the axle on the passenger side. You can see the big ½" bolt here along with my "massaged" track bar mount.


The other end you'll be working with is a little steel cave on the drivers side that makes easy extraction of the cotter pin impossible. Using an extendable mirror let me see what the hell was going on. I ended up breaking the ends off the pin and using a 2' breaker bar to turn the nut off.


After removing the old track bar, I shook the Jeep back and forth from both sides to let it settle into its natural center. It took a few tries to get the length just right on the track bar but the adjustments were easy to make. The FSM calls for 40 ft lbs on the axle mount bolt and 60 ft lbs on the ball stud. Because of my previous issues with the axle mount and larger bolt, I torqued both to 60 ft lbs.


I will have to get an alignment as my steering wheel is at about 2 o'clock when going straight. Handling felt normal on the ride home. After the alignment, I'll again traverse the two spots that have consistently given me death wobble. I'll report back shortly.
 
#337 ·
Even after installing the SYE, I was still getting some driveline vibrations, so I began to look into it and found that changing to a double-cardan shaft should include changing the angle of the pinion yoke as well.



I used a cheap magnetic angle finder. The driveshaft is easy enough.


Ideally you disconnect the rear driveshaft and rotate the yoke to a vertical arrangement and then measure the angle from there. I didn't feel like all that, so I took two identical sockets and put them on each strap bolt, which brought a flat plane out from the u-joint enough for me to use the angle finder with driveshaft in place.


After getting both angles, it was a simple matter of arithmetic. See http://www.wolferacecraft.com/pinionangle.aspx for more info.
With my 3" lift, a 4° shim should fix me up. I sourced a pair from BDS for around $20.



I got started a couple nights ago. The shims went in no problem but while I was on the creeper I found my rear brake line was rusted all to hell plus leaks from my front pinion seal and the pressure hose on my power steering pump. Going to address those this weekend.
 
#338 ·
Got the YJ hose installed and the front section of the original brake line flared and ready to go. Just got a fresh piece of hard line to replace the run from the front fender to the rear hose. Taking a lunch break.

Comparing the YJ line with the stock XJ line - 3-1/8" longer
Reptile Snake Scaled reptile Cable Tail
 
#340 ·
Thanks! I'm ordering tires later this week. A set of rock sliders and that's all the plans I have for it as of right now.

(I might look into a WJ rear disc swap, poor man's high steer, or a Detours Tailbone down the road but all have zero priority.)
 
#341 ·
I can't recall exactly what for but I recently removed my center console when doing some cleaning. I'd noticed for some time the rear section of the center console was floppy but hadn't paid it much mind. When I got the console out, I found the lousy plastic mount in multiple pieces. I don't remember the exact price but the OEM replacement, bound to end up in the same condition, was over $100.


I pulled it out and stared at it for a few days until happened into Lowes and inspiration hit. I found these straps in the lumber section with the hurricane clips. I used one, cut in half, for this entire project.


To start with, I put them in a vise and added a simple 90° bend.


If you've never had your center console mount out before, it's pretty simple. (I'll add a photo below later.) First, assuming you have an AW4, grab the shifter handle and pull straight up with considerable force. Do not twist the handle as it will break internal components. With it removed, pop off the trim panel with the gear selection indicator. There's two wires going to a light for it you'll have to unplug. Next, remove the trim panel for the transfer case shifter. It too has a light that will have to be unplugged. Inside these openings you'll find two screws that secure the center console to the shifter mounts. Remove both. Empty out your center console and inside you'll find two screws. Remove them as well. The console should now be free from the floor. To remove it, pull the emergency brake all the way up and slide the console towards the back seat while lifting the back of the console up towards the roof. Take your time as you'll have to work around the 3 levers to finally remove the console. After that, slide out the ductwork that runs to the rear seat and you'll find things looking more like the pictures that follow.

With what remained of the OEM mount reinstalled, I began aligning the new brackets.


I ended up fitting the broken original legs back in place to align a hole in my metal straps with the old screw hole.


When the new brackets were aligned, I peeled back the carpet as best I could and used self-tapping screws to fasten them to the floor. I used two screws per leg.


I grabbed some screws from my collection and tapped the holes in the brackets to fit.


The end result was a center console able to move just enough as to not break itself but otherwise securely mounted to the floor. :thumbsup:

:rtft:

I've also become aware of some USA-made metal replacements for $55. They seem very nice, although most of you probably have enough change in your center console to fix your mount with my cheapskate method. If you're interested in a more bolt-in option, you can find them at http://www.cherokeeforum.com/f74/1997-2001-jeep-xj-metal-center-console-bracket-158249/
 
#347 ·
For much of this build, practicality and fuel efficiency were major concerns. Now at ~3" of lift and 31" MTs, those concerns seem foolish. Too finish killing any aerodynamics I once benefited from, now I want a roof basket so I have a place to strap a shovel and Hi-Lift. It'll give me a place to stow the rear seat and gear off the ground too when I car camp.
 
#349 ·
I am not sure at all that I'll be able to fit a fullsize spare in the stock location. My arrangement is snug as it is. I'll follow up when I get the spare mounted.

 
#350 ·
Love your setup, I believe Ive going to have to break over and trim my lower valance like you have done. Been a while since of read through your build, what brand tow hook setup do you have? After a fellow Jeeper got into a mess this weekend, getting some solid recovery points is next on my list.
 
#351 ·
Losing those 4" of plastic has helped a ton! Definitely one of my favorite mods.

The hooks are C4x4 hooks. Blast the cheap chrome off the hooks and paint them before you install them. They get pretty rusty over the course of 3 years. http://www.jeepinoutfitters.com/scripts/prodView.asp?idproduct=40 Despite not being pictured, the kit does come with hooks.

 
#352 ·
Thats the ones I was looking at. My main thing is I'd really prefer d-rings over the hooks, but the only thing like that I found was like an additional 60 bucks. For that much money Ill just build a bumper lol.
 
#353 ·
#354 ·
Thanks! I may have to fab something up or get creative.

Hows the Treadwrights doing? Im really thinking hard on those. Ive got 3 Firestone Destination MT's on mine right now and while they have served me well, one tire to complete the set is 200+ shipped, and my 3 I have are already at 50-60%. Id probably be better off to get all new tires.

Im mainly concerned with offroad durability with them.
 
#355 ·
They do great back and forth to work, 5 miles a day. Felt great in the couple inches of snow we got over the weekend. Not sure when I'll be able to get them in the dirt. Probably not until spring.
 
#356 ·
Sounds good, I have a similar short drive to work. Speaking of spring, Im dying to get the XJ out in the woods with the windows down, maybe do some grilling out lakeside. Half the fun of Jeepin is the things we do with them to get the family outside and off the iPhones and computers. Could be why I dig the build. Its everything you need and nothing you dont.
 
#360 ·
Many years ago, I wanted to replace the 2.8L in my 85 S-10 because the valve covers leaked. Dad explained to me it wasn't a big deal but I didn't want to hear it. He didn't press the issue. He did give me a ride to the credit union, co-signed on my first loan and helped me install the crate 3.4L upgrade. If I ever found that truck, I'd do everything I could to buy it back. I put over $6,000 into it over the 4 years I had it. Anything that creaked, squeaked or leaked got replaced with top-notch stuff. Moog ball joints, Spicer u-joints, etc. I built it to keep...and then got rid of it.

My 87 Silverado got treated the exact opposite. Run it until it fails! That truck has been beat to hell but the tactic has worked well. I've wheeled it down ATV trails with the mirrors folded against the doors. I've passed out drunk underneath it and slept like a baby in the oily grass. I drowned the original engine playing in hurricane flood waters. It's run for the last 5 years with a few chipped ring gear teeth in the rear axle from it eating the spider gears, virtually ever sensor needs to be replaced and the sliding rear windows are locked with two sections I out of a storm window frame. That said, it falls back into being a DD anytime the Jeep is down (so, a lot) and fires right up every time I hop in it. I've got everything I need to to swap in 3/4-ton axles and to regear to 4.10 gears...except 8-lug rims.


I've tried to learn from my previous builds and strike a balance on what I do with my Jeep. I feel like I've been successful with it so far. Doing everything the hard way has kept my investment to a minimum. Parts and solid repair/mod info are readily available and I hope I can hang onto it for a good long while.

Again, thanks for the kind words. It's good talking to a fellow boring married guy. :D You need to update your sig to link to your new build thread! I'm enjoying following it too.
 
#361 ·
Many years ago, I wanted to replace the 2.8L in my 85 S-10 because the valve covers leaked. Dad explained to me it wasn't a big deal but I didn't want to hear it. He didn't press the issue. He did give me a ride to the credit union, co-signed on my first loan and helped me install the crate 3.4L upgrade. If I ever found that truck, I'd do everything I could to buy it back. I put over $6,000 into it over the 4 years I had it. Anything that creaked, squeaked or leaked got replaced with top-notch stuff. Moog ball joints, Spicer u-joints, etc. I built it to keep...and then got rid of it.

My 87 Silverado got treated the exact opposite. Run it until it fails! That truck has been beat to hell but the tactic has worked well. I've wheeled it down ATV trails with the mirrors folded against the doors. I've passed out drunk underneath it and slept like a baby in the oily grass underneath it. I drowned the original engine playing in hurricane flood waters. It's run for the last 5 years with a few chipped ring gear teeth in the rear axle from it eating the spider gears, virtually ever sensor needs to be replaced and the sliding rear windows are locked with two sections I out of a storm window frame. That said, it falls back into being a DD anytime the Jeep is down (so, a lot) and fires right up every time I hop in it. I've got everything I need to to swap in 3/4-ton axles and to regear to 4.10 gears...except 8-lug rims.

I've tried to learn from my previous builds and strike a balance on what I do with my Jeep. I feel like I've been successful with it so far. Doing everything the hard way has kept my investment to a minimum. Parts and solid repair/mod info are readily available and I hope I can hang onto it for a good long while.

Again, thanks for the kind words. I'm enjoying following it too and it's good talking to a fellow boring married guy. :D You need to update your sig to link to your new build thread!
Interesting! A nice balance is what Ive wanted to achieve since day 1, but as a side job I used to do autobody repair on vehicles I picked up from auction to turn around and sell. Unfortunately that morphed into my personal vehicles. Id buy something, fix it up how I want, then get bored with it after the process was all said and done and sell it. My goal here is to keep my current Jeep as my "ol reliable", so to speak. Something that stays around to serve the role of winter transportation or just to get out in for leisure, but good enough to DD.

When I spell it out like that, our desires arent so different lol. Thanks for the reminder on the link, I just realized i never added it to my sig. And yes, just another boring married guy. Starting to become a rarity on JF. Been getting a lot of the "Im 15 and whats the best lift kit" kinda crew lately. :eek:
 
#362 ·
It's been weird. CF, NAXJA and here have all been inundated with noob questions lately. I had no idea the crowd here was so young until somebody put up an XJ owners age poll a couple months ago. I guess there's constantly more of them. Fortunately XJ prices seem to be going up so at some point we'll have these rare, sought-after rigs (like the Sammies are getting be) while everybody else is buying IFS stuff and wondering why they can't make it up stuff.

In build news, this morning I placed my order for a set of AJs standard sliders with some minor customizations.
 
#380 ·
Im 17, I try and keep my noob questions to a minimum.
I also wheel with some skill, I may get into it but not as bad as my friends do.
and IFS :nono:
The worst is when something is asked when the same question is just a few lines below it making the fact that the noob didn't search glaringly obvious.

But legitimate questions are okay anytime. You seem to be doing great with your build!
Kind of what you said. I don't think anybody has a problem with noobs and their questions, it's just at times like, "c'mon! Use some sort of search. Google is your friend! Read through the sites some and find your info!" Too many people just aren't willing to put the time into researching what to Di and want people to be like, do x, y, and z. If you're having trouble with something ask away!
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top