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I have used the Wilton once or more. Limited success with taps. I have also used carbide drills on taps and drills. Carbide drills snap real easy. Any side load, and snap. And then its EDM time. I'm in a similar situation. I broke a drill, on a bolt to a Chevy Avalanche. Not fun.

I used straight 1-tons on my first setup. It had Rusty's OTK trackbar. On the Second with Stinky Fabs, I had to use offsets. Also, I ran or run RuffStuffs diff cover with the steering stabilizer bracket. If properly setup, it is not needed. I used Ruffstuffs 1-ton Crossover kit on the first. I...

I have for a 3" lift LCA 16.09, UCA 14.92

I have the Stinky Fab OTK Trackbar setup. Also, his Trackbar brace set up. I like it. Mines with a WJ BB setup. The guy who did the fab work, used a Tera-Flex knuckle on his TJ. Similar setup. Mine are for the road, so I used 1-ton GM TREs.

2007-08 Doge Nitro Rotors are a direct fit for a WJ Big Brake Swap. Give up about 1.5mm of the OD.

On the Wheel Hub bearings, Keep the bolts in there. But a socket on them. If you turn the steering wheel, and socket contacts the frame or something else it should pop it free. Then you can tap it out with the other bolts. Keep a socket on the heads, as not to damage them.

I am going through this too. I did have my EMC tested. I sent mine to ECM Repair1 in Tilden IL. They didn't find an issue with it. Bench fee was $96 or so. The EMC was cleaned. Good luck.

When using POR 15, I put some Saran or Cling wrap between the lid and can. This does two things. First, helps keep the lid from attaching to the can. The other, it helps to keep the POR 15 'fresh'. I like to use the small cans. Still, it depends on the area you are going to cover.

I don't know what Jasper's warranty is. Also, time as to when you replaced the motor. Still, as above, at 50K for a harmonic balancer to fail, is pathetic. I'd send an email or call Jasper. Worth a try.

I had a harmonic balancer go bad. I hope you caught it in time. Another thing I look at with XJs, is the rear steel brake line. I replace them with the prebent SS lines.

First you should clean the frame. Get off the oil, grease and undercoating. Probably then remover any heavy rust. Then use a degreaser. POR 15 does sell a degreaser. I'd use whatever. Then the metal prep. Then the POR 15. I like two coats. Then two coats of whatever paint. You have to apply the...

Any particular model? I see a few on EBay. About $200 to $350. Also, it was pointed out to me that my electric fan setup might cause the issue. The temp sensor is out of the flow of the coolant. I'll have to check that at some point.

Going through misfires myself on an '00 XJ. The misfires started on the old motor. Around 280K on it. Then a piston skirt cracked off. Not fun driving 30 miles or more back home. I had been working on a mini- stroker so I finished it up and installed it. It ran OK for a while during initial run...

As above. I had this happen on a Ford Tempo. Would be doing 60 mph on the highway. Then I'd have to have the petal to the metal to do 50 mph. Then it would go back to normal. Changed the O2 and it was fine. Still, just a guess.

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I replace the Harmonic balancer on the XJ's I acquire. They are like $50-60. I did have one go bad. It cost me a crankshaft. Fortunately for me, a neighbor had a spare. Even used the main bearings. Sort of traded 4.0L engines over the years. One other thing to check, might be the distributor...

POR-15 says not to use a rust solvent. I'd use Spray Nine Grez-Off for heavy gunk. Then card off as much rust as you can. Degrease again. POR-15 has their own degreaser. Use their metal prep. The POR-15 at least twice. Then coat with a paint. There are other stuff. I am trying Agraguard. I...

I'd check the harmonic balancer. Place a white paint strip through the inner and outer ring. Another would be the AC compressor clutch.

I did have to have some nuts welded on the WJ knuckles with the R17's. I do run the R16 Rims with the WJ Big Brake set up. I had to do some clearance on the Ironman Swaybar extensions. You might check the backspacing between the rims you have and some WJ rims.

On my XJ's I ran a 32- 10.5 width and presently a 31-9.5 or so. The actual tires are Metric. I do run Ford 8.8. You will need to run spacers or the Yukon axles.