Money Pit or Good project - 96 XJ Classic Build thread - JeepForum.com
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post #1 of 185 Old 10-13-2010, 07:33 AM Thread Starter
Azzy
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Money Pit vs Good project - 96 XJ Classic Build thread

Specs:
1996 Cherokee Classic
Designation: J2
$500 from a local
260K+ Miles
spare transmission
Doesnt shift properly with either
Inspected until 2-11

Needs:
Thermostat housing (took to fix my wife's 01)(Fixed!)
Front sway bar mounts
Steering box swapped with low milage rescue and rebuilt, new steel mounting plate
Tires (Mounted 2 31x10.5x15 treadwright bulldogs, waiting on 2 other rims to get back to me for the other 2, and then have to find a spare)
rear window glass (Fixed!)
neutral safety switch (Fixed!)
cleaned real good inside
various trim screws (parts all seem to be missing at least one)
bigger battery tray
brake lines (too rusted for my tastes)
shocks (have new)
2-3" lift (installed RC Stage 2 with add a leaf rear)
Driver side door re-tweaked
Locks cleaned and re-keyed cleaned and cot all the locks working


Got some more photos of J2 up last night (we started numbering them).

Picasa Web Albums - Bryan - XJ2

Just got the build sheet:
Code:
Sales Code     Description 
*J5 Cloth/Vinyl High-Back Bucket Seats
AHGP Spring Special Group
APAS Monotone Paint
ARWP Sport Decor Group
AWH Power Equipment Group
BAUS 117 Amp Alternator
BCDS 500 Amp Maintenance Free Battery
BGAS Power Front Disc/Rear Drum Brakes
CADP High Back Bucket Seats
CDBP Reclining Front Seats
CFMS Rear Folding Seat
CGTS Driver Air Bag Only
CKAS Carpets - Floor and Cargo Area
CKNS Cargo Compartment Carpet
CKTS Cargo Tie Down Loops
CKXS Rear Back Panel Cut Away
CLEP Front & Rear Floor Mats
CSAP Spare Tire Cover
CSRS Passenger Assist Handles
CUFP Full Length Floor Console
DGB All 4-Speed Automatic Transmissions DGSS 4-Speed Automatic AW4 Transmission DHAS Lock-Up Torque Converter DHNS Command-Trac Part Time 4WD System DHSS Floor Mount Automatic Shift Lever DJHS Dana M30/181MM Front Axle DMDS 3.55 Rear Axle Ratio DRAS Corporate 8.25 Rear Axle EAAC All Engines ERH 4.0L I6 Power Tech Engine GAL Deep Tint Sunscreen Glass GBBS Tinted Windshield Glass GCBS Front Door Tinted Glass GEHS Fixed Door Vent Glass GFA Rear Window Defroster GRZP Left Remote Mirror GSZP Right Remote Control Mirror GTZ Manual Remote Mirrors GVAC All Vehicles W/O Power Mirrors GXMP Remote Keyless Entry HAAP Air Conditioning HGDP Deluxe Insulation Group JAZS Analog Instrument Cluster JBFS Instrument Panel Black Bezel JCAS 85 MPH Primary Speedometer JHAS Var Intermittent Windshield Wipers JHBP Rear Window Wiper/Washer JJAS Cigar Lighter JJBS Dual Note Electric Horns JPAP Power Windows JPBP Power Locks LAJS Headlamps On Warning Chimes LBCS Glove Box Lamp LDBP Cargo Compartment Lamp LMAS Halogen Headlamps LPSS CHMSL Lamp MB1S Black Front Bumper MB5S Black Rear Bumper MCAP Front Bumper Guards MFKP Body Color Grille MHAS Black Windshield Moldings MMCS Upper Door Frame Moldings MMGS Belt Moldings MMKS Body Color Drip Trough Molding MNAS Black Door Handles MUKS MOPAR Chrome Bodyside Molding MWGP Roof Rack NAA Federal Emissions NBKS EVAP Control System NFAS 20 Gallon Fuel Tank NHM Speed Control
PW1 Stone White Clear Coat
QW1S Stone White C/C
RAAC All Radio Equipped Vehicles
RAF AM/FM Cassette Radio
RCDP 4 Speakers
RDDS Fixed Long Mast Antenna
SBAS Power Rack and Pinion Steering
SCGP Leather Wrapped Steering Wheel
SDAS Normal Duty Suspension
SHAS Front Stabilizer Bar
SHCS Front and Rear Stabilizer Bars
SUAP Tilt Steering Column
TBCS Compact Spare Tire
TBLS Inside Mounted Spare Tire
TRNP P225/75R15 OWL Wrangler AT Tires
TZAP Goodyear Brand Tires
WJ3P 15X7.0 Aluminum Wheels
YAAS Build To U.S. Mkt. Specifications
ZFJP Spring - Left Front
ZFTP Spring - Left Rear
ZUJP Spring - Right Front
ZUTP Spring - Right Rear 

Our records indicate that the following recall campaign(s) have not been performed by an authorized dealer:

                Recall #                  Description
                   E22             REPROGRAM PCM AND INSPECT CATALYTIC 
CONVERTER    
                   879             FRONT BRAKE ROTORS  

We suggest that you contact your local authorized Chrysler, Dodge, Jeep.
or Ram dealer to make arrangements for an inspection and, if necessary, corrective action at no charge to you.
The more I look at it, the more daunted I get by the amount of rust under there. Someone give me an honest eval on this? Money pit, or fun project? I want a project, and a driver. Would like them to be both (its getting crowded in our yard and driveway, no garage hurts at times). The wife's is an 01 sport (J3) that is in great shape, and with the saturn and 2 bikes.... well...

Pulled parts from the donor, and will pull up pics as soon as I find that memory card. But, we pulled good rear leafs, a good 8.25 rear, 2 wheels, a new trans computer, a full front axle and brakes (in good shape so far), a factory clock and an armrest. Got a steering box as well, but more on that later.

Not bad for 2 hours and a small bit off change.

Now on to Progress!!!!



Finally, progress!
https://www.jeepforum.com/forum/f11/m...l#post12068827

Tire changing in 20 seconds!
https://www.jeepforum.com/forum/f11/m...l#post12086436

Steering box rebuilt
https://www.jeepforum.com/forum/f11/m...l#post12166324

more front end work, timing chain, fan clutch, etc
https://www.jeepforum.com/forum/f11/m...l#post12166413

Troubles with the gauge swap:

https://www.jeepforum.com/forum/f11/n...uster-1266846/

Nests vibes, and other oddities in the blower:

https://www.jeepforum.com/forum/f11/h...atman-1266746/

Pulling the front axels:

More fun, with brakes! :https://www.jeepforum.com/forum/f11/p...-pads-1289759/

Not so fun stalling issues: https://www.jeepforum.com/forum/f11/o...to-4h-1291129/


Last edited by Azzy; 11-22-2011 at 08:56 PM. Reason: Update 11-22-11
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post #2 of 185 Old 10-13-2010, 07:43 AM
lowicz96
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1995 XJ Cherokee 
 
Join Date: Oct 2007
Location: Flint/Asheville
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It doesnt look bad compared to the 96 i had that you could flintstone it. I would take the carpet and seats out to fix the rust inside and out.

The shifting problem could be a sensor like TPS or NSS.

Looks like a good project to me but will/can be a money pit too. I bought my 95 for $500 bucks too and i have somewhere between 3K-4K invested in it overall. But is lifted, locked, broken parts upgraded and i know its going to last till 300K miles

Project/DD - 95' Cherokee Sport, 2 Door, Converted to 4x4, AX-15, NP231, Black and lots of other goodies

88' Cherokee Limited - RIP

Sold - 96' Cherokee Sport 4x4, 2 Door, AW4, NP242, Its the girlfriends now!!
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post #3 of 185 Old 10-13-2010, 07:45 AM Thread Starter
Azzy
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Floor.. well.... grab a beer, this one is a hoot.

Previous owner cut out the rusted through floor panels. He then took rivets, a torch, and an old Buick hood, and replaced them. Sealed it with expanding foam.

Honestly, its interesting, and serviceable for now, but solid and will probably be replaced at some point.
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post #4 of 185 Old 10-13-2010, 07:49 AM
lowicz96
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I used a hood from a chevy corisca (we had a car bash event at school) to repair alittle floor rust. I welded mine in thought

Project/DD - 95' Cherokee Sport, 2 Door, Converted to 4x4, AX-15, NP231, Black and lots of other goodies

88' Cherokee Limited - RIP

Sold - 96' Cherokee Sport 4x4, 2 Door, AW4, NP242, Its the girlfriends now!!
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post #5 of 185 Old 10-13-2010, 08:07 AM Thread Starter
Azzy
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Any suggestions on stopping the rust on the chassis? Right now I dont have access to much to lift the car up, I would be using ramps in the backyard on cement patio slabs.

I plan on working / storing it back there, and am planning on sacrificing grass and laying down a tarp underneath so the moisture doesnt kill it over the winter.
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post #6 of 185 Old 10-14-2010, 08:54 PM
Spencer43783
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Your best bet for rust removal is a wire cup brush on a grinder. Once it's off hit it with some spraypaint/bedliner and you're good to go! I need to do the entire bottom end of mine too so I feel your pain! It's time consuming but doable. Oh and a face shield would be a good investment as well!

1998 Cherokee Sport 4.0L-AW4-NP231-C8.25--Black, trim removed and chopped. 31" Goodyear Wrangler Duratracs. 3" lift coming soon.
1984 Grand Wagoneer--Sold. I'll miss the old girl.
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post #7 of 185 Old 10-15-2010, 01:20 AM
Jameslol
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Everyone says to clean it and paint with por15 (expensive but i have not heard a single negative comment about it) besides the price at least.


Also i would just get another xj that isnt molested from head to toe with rust and use that as a donor

Black 1996 Jeep Cherokee Sport, 4.0, 4WD, NP231.
31 inch Yokohama Geolanders.
3" Rough Country AAL Kit. ZJ tierod.
C4x4 Front tow hooks.
Nates 4x4 rear bumper w/receiver and shackles
Iron rock offroad double shear adj trackbar
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post #8 of 185 Old 10-15-2010, 01:02 PM
codecat
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Go for it! Fix the rust and just look for used parts to keep the cost down. Even lift kits and tires. There's plenty out there!
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post #9 of 185 Old 10-15-2010, 06:32 PM
Spencer43783
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IMHO POR15 is a little much. It's a rust convertor/paint and yes it isn't cheap. Rust convertor is basically an acid that 'converts' the metal/rust to a paintable surface. Most directions will tell you to treat it like paint though: remove the excess rust, clean the surface, ect. So I don't really see the point. If you're building a high-end trail rig and want the best of the best, go for it. If you're just an average joe like me, a wire cup brush on a grinder and some paint/bedliner will do just fine

When you're getting suspension parts get Moog or NAPA brand. I buy everything from NAPA. Period. I've learned my lessons.

A lot of the other stuff you listed can be snagged from a junkyard, or as someone else mentioned, buy a donor rig. Here's a link you'll want to check out if you haven't already https://www.jeepforum.com/forum/f11/b...fit-xj-847303/

1998 Cherokee Sport 4.0L-AW4-NP231-C8.25--Black, trim removed and chopped. 31" Goodyear Wrangler Duratracs. 3" lift coming soon.
1984 Grand Wagoneer--Sold. I'll miss the old girl.
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post #10 of 185 Old 11-01-2010, 09:03 PM Thread Starter
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Score!

Found a whole new rear hatch on Cl for $50 local, so there goes having to get a new rear window.

Pro: hatch is in good condition
Con: Different lock, no key. J2 is white.. hatch is red.

Nothing some rattle cans cant fix, right?
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post #11 of 185 Old 11-02-2010, 08:54 AM
240kat
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Quote:
Originally Posted by Azzy View Post
Score!

Found a whole new rear hatch on Cl for $50 local, so there goes having to get a new rear window.

Pro: hatch is in good condition
Con: Different lock, no key. J2 is white.. hatch is red.

Nothing some rattle cans cant fix, right?
if a key is what's making the can rattle :rimshot:
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post #12 of 185 Old 11-11-2010, 10:54 PM Thread Starter
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Got a new cluster to go in this weekend, rebuilt the NSS the other day.

Planning on ordering a 3" rough country add a leaf, but not sure of the rear end spec. Here's a pic:


Axle mics to 3.08" OD.

(looks like its leaking as well..... ugg.)
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post #13 of 185 Old 11-12-2010, 08:14 AM
Spencer43783
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It's a little hard to tell with the tiny pic but it looks like the C8.25. The C8.25 has a flat lip on the bottom that hangs lower than the diff cover. Also if you look on the top of the diff towards the driveshaft there's some bracket type things if it's the Chrysler. The D35 has no lip and no bracket stuff.

Oil tends to draw moisture so leaks, especially diff leaks, often look 100 times worse than they really are. Clean off the diff cover well and put a new plug in. If you feel like messing with it, pull the diff cover, clean and paint it, spray the gears out with brake cleaner, reinstall cover, top it off and put a new plug in.

1998 Cherokee Sport 4.0L-AW4-NP231-C8.25--Black, trim removed and chopped. 31" Goodyear Wrangler Duratracs. 3" lift coming soon.
1984 Grand Wagoneer--Sold. I'll miss the old girl.
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post #14 of 185 Old 11-12-2010, 08:32 AM
240kat
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Quote:
Originally Posted by Azzy View Post
Got a new cluster to go in this weekend, rebuilt the NSS the other day.

Planning on ordering a 3" rough country add a leaf, but not sure of the rear end spec. Here's a pic:


Axle mics to 3.08" OD.

(looks like its leaking as well..... ugg.)
think that's a 27-spline 8.25
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post #15 of 185 Old 11-12-2010, 08:39 AM
mosh-n-roll
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Yeah that looks like an 8.25 to me.

I bought a 1998 4.0 sport, 4 door, 5 speed with 150,000 on her in february for 500 bucks. It wasnt running when I bought it but I figured me and a few buddies of mine could get it going. Since I bought it I had to put about 400 bucks into it to get her going. Now she's on the road and runs mint. I don't regret buying it one bit. Now I just wish I had some spare dough to buy a lift :/ lol
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