Trying to Help A Friend With his XJ's Rust... - JeepForum.com
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post #1 of 11 Old 05-02-2021, 04:42 PM Thread Starter
Hoosierman
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Trying to Help A Friend With his XJ's Rust...

I hang around the ZJ forum since that's my current project vehicle. However, a good friend of mine of many years just bought a '96 XJ 4.0 back in January and I've been helping him here and there. So on wednesday I am getting some new tires for mine, going to look at his rust problem. See, the headliner has been removed and sure enough just above the windshield there is a leak and the roof panel has been rusted on the interior. So I thought that I would ask the XJ folks what can be done at home. There is a metal panel of some sort that's being held in by two rusty screws- one of which is probably seized. So any guidance on what to do would be great.



Here's the picture of the mess in question:

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post #2 of 11 Old 05-03-2021, 01:01 AM
Ralph77
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So I know you said there is a metal plate held in there by 2 rusty screws.
Is that what has the hole in it that I can see?
Or is it my eyes playing tricks on me and that is all just the roof? LOL.
Cause if that is a separate panel I have never seen anything like that before in the roof.
This is what I am used to seeing. See the shot below.
If that is the case if it were me I think I would remove it.
But try to figure out why it is there in the first place before I do.
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post #3 of 11 Old 05-03-2021, 08:56 AM Thread Starter
Hoosierman
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Might that plate have anything to do with the lights this Jeep likely had mounted on the roof when it was in service with the Michigan State Police?
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post #4 of 11 Old 05-03-2021, 10:17 AM
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Quote:
Originally Posted by Hoosierman View Post
Might that plate have anything to do with the lights this Jeep likely had mounted on the roof when it was in service with the Michigan State Police?
Something like that did pop into my head.
Seeing how it was a State Police vehicle might explain it.
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post #5 of 11 Old 05-03-2021, 10:24 PM Thread Starter
Hoosierman
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Perhaps I should have mentioned that in the original post.

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post #6 of 11 Old 05-03-2021, 11:03 PM
Ralph77
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Quote:
Originally Posted by Hoosierman View Post
Perhaps I should have mentioned that in the original post.
That might make the XJ a little more special.
Could be a Police Version one.
They came with options that are a little different then a regular XJ.
For instance.
Does it have a rubber floor and not a carpet?
Does it have a speedometer that goes to 120 MPH instead of 85 MPH.
Does it have a switch that says Ext Idle?

Edit:
If the Jeep has the 242 transfer case that might be different too.
The other things I mentioned are definitely things that come in a Police Version XJ.
But I am under impression that it has a different 242 transfer case then a regular XJ with a 242.
I think it has a beefier chain or something like that.
But not sure.
And if it does I think I have read that getting parts that are specific to that transfer case can be challenging.
But I also think it is not all the parts inside that are different. Just a few pieces here and there.
Plus I am guessing it has a D35 rear diff with ABS.
Which is less desirable then an 8.25.
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post #7 of 11 Old 05-04-2021, 07:02 AM
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Eeew, that roof looks nasty. I would remove that rusty plate and then somehow deal with whatever rust is remaining.

I have dealt with the windshield rust before. Option "A" is to remove the windshield mouldings, clean up the space behind it, and literally replace it with a couple tubes of some kind of rubberized caulking. Literally use the caulk to create a new moulding. Tape off the windshield glass and metal and troll it over to make it look decent.

Option "B" is to cut out the windshield and sandblast as much rust as you can see. Fill the voids in the metal with lots of JB weld or fiberglass reinforced bondo or whatever it takes. Prime, paint, clear, and it should last you half a decade or better. The latter option is not fun and is time consuming, but it works pretty well. This is the way to go to ensure that the rust doesn't crack the windshield glass.
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post #8 of 11 Old 05-04-2021, 10:09 AM Thread Starter
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Matter of fact it is an MSP XJ. Even has the original MSP blue paint job that's otherwise rust free on the outside. Trying to do what we can to preserve the Jeep. Hell it's just getting started with it's life, I don't think it's even got 140k on it yet.

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post #9 of 11 Old 05-04-2021, 04:17 PM
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Quote:
Originally Posted by Ralph77 View Post
That might make the XJ a little more special.
Could be a Police Version one.
They came with options that are a little different then a regular XJ.
For instance.
Does it have a rubber floor and not a carpet?
Does it have a speedometer that goes to 120 MPH instead of 85 MPH.
Does it have a switch that says Ext Idle?

Edit:
If the Jeep has the 242 transfer case that might be different too.
The other things I mentioned are definitely things that come in a Police Version XJ.
But I am under impression that it has a different 242 transfer case then a regular XJ with a 242.
I think it has a beefier chain or something like that.
But not sure.
And if it does I think I have read that getting parts that are specific to that transfer case can be challenging.
But I also think it is not all the parts inside that are different. Just a few pieces here and there.
Plus I am guessing it has a D35 rear diff with ABS.
Which is less desirable then an 8.25.
Obviously I'm a bit out of my depth with police spec XJ's as I've never even seen one but I thought the most obvious distinguishing feature was the column shift & no centre console - to make room for all the specialist equipment.

If the TC is different then it's likely an HD, isn't it? But that should be clear from the tag.

Oh, & I do recall someone in our "ex-Black & White Owners Club" or whatever they call themselves, informing interested onlookers at a car show that all gennie cop cars have the same brown vinyl interiors.
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post #10 of 11 Old Yesterday, 12:47 AM
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Quote:
Originally Posted by UKXJ View Post
Obviously I'm a bit out of my depth with police spec XJ's as I've never even seen one but I thought the most obvious distinguishing feature was the column shift & no centre console - to make room for all the specialist equipment.

If the TC is different then it's likely an HD, isn't it? But that should be clear from the tag.

Oh, & I do recall someone in our "ex-Black & White Owners Club" or whatever they call themselves, informing interested onlookers at a car show that all gennie cop cars have the same brown vinyl interiors.
If I am right about the TC, again if (LOL), yes it is supposed to be HD.
I just think this from something I read on the internet awhile back.
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post #11 of 11 Old Yesterday, 10:05 PM
rjbruzan
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Remove the extra sheet metal. Wire brush the loose rust off it you may need to go under the bracket that holds the sun visors. Then coat the entire rusted area with a product like Rust-Mort which contains ospho, it seals the rust so it can be painted successfully with any decent brush on paint like Rust O leum.

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