BigNuge’s 99 XJ

Mid weekend update....had some help for a while, got the axle back in the rear.




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Got the new calipers in, front brakes all put together. I ran out of brake fluid for bleeding the brakes, I’ll get them bled tomorrow. Had to order the new ebrake cables, those are due in next week.




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Only limited progress over the last couple days. Ran out of brake fluid, got more but didn’t have a second person to help bleed (plus the driver seat isn’t in, so bleeding like that isn’t very convenient). So bleeding the brakes isn’t done yet, but they’re all together.

Got all new ebrake cables in. Nice surprise, found rear brakes are brand new! Shoes, hardware, adjusters...all new. Got the rears all back together, new ebrake cables all the way to the handle. New adjuster assembly due here tomorrow. Got the adjuster housing relocated 3” towards the rear to give the driver side rear a little extra slack, it was more taut than I was comfortable with.

Got the wheels back on, it was great to have it rolling on it’s own again! Adjusted the steering link a bit, wheels are way off after the lift. With no engine it’s sitting waaaaay high, so I am not going to worry about getting it lined up yet.

Got the driver side interior floor section painted with the undercoating like the other side, came out good. A day after the paint I got the floor put back together with carpet and whatnot.

One unfortunate issue is one (15 wire) connector on the driver side kick panel got damaged during the use of a wire wheel on my grinder. The connector got busted up, and 4 wires got ripped right out of the connector. I have ordered a set of 8 pin connectors to make up 2 connectors to replace the 1.

I’m headed out on a upland bird trip next week, so I probably won’t be doing much more on the Jeep this week....got to start getting things ready for that trip. Really, I was hoping to have the XJ ready for it....but that won’t be happening


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Got the Jeep rolled outside for the first time in weeks. Good to see the sun shining on it!




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Hey everybody....just a quick hello to let you know I haven’t died...

Been a crazy busy month, house renovations, fall/cold weather prep, and work gets busy in the fall in the industrial boiler business.

I have actually started prepping the donor XJ for engine removal. It’s on the lift, and I have got the transmission all but ready for the pull. A few more “under side” things and I’ll drop it and get the topside ready for pulling the motor. Can’t wait to get the motor into the 99, see it move under its own power again!

Stay safe everybody....


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Well....blink and 2 months have gone by!

Progress on the XJ kind of froze, but I have gotten some solid time into it over the holidays.

Got the donor motor out of the 96, separated the tranny and Tcase, put those in storage for future needs. Got the donor motor on a stand and prepped, sensors and whatnot transferred over from the 99’s motor, flex plate transferred, intake and exhaust manifolds swapped, tune up done, valve cover gasket done, oil filter housing orings done.




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Got the pan gasket and new RMS done, installed the new water pump, motor is ready to be mated back up with the transmission ahead of schedule!




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Had a change of plans, so I was able to get some time in the shop again today.

Got tranny bolted up, hoisted it all into the XJ. Its great to have the motor back in there! I just got it bolted up, nothing wired yet. I’ll get to that later this week.




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Back at it tonight...almost ready for fluids and test fire!




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Boom....it’s alive.


https://youtu.be/bFhoJJaV03A


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Got the nose put back together, rear frame tie-ins painted and installed, stock rear bumper back on (for now, proper rear bumper will come sometime in the future).

Next is figuring out the SYE yolk. I didn’t think about the complication of getting the ujoint in the cardan to attach to the repurposed yolk I used for my SYE. Got to get that figure out so I can get the rear driveshaft back in....I’m moving it around as a front wheel drive for now...lol.




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And that brings me to where I am now (as of 1/15).


Rims and tires are ordered. Went with the Falken Wildpeak A/T3s in 33x12.5x15

Ordered a set of simple black steel wheels in 15x8 (lug nuts and center caps to go with).

I was really trying to not spend the $$ on the IRO hack and tap, but I see Im going to have to. The only upside is that I already have the tcase trimmed and tapped....so It will be a quick/simple bolt-up.

Im going to be carful with the shop I choose for the alignment. I dont want the new tires munched with a bad alignment. Anyone in my area (seacoast NH) that knows of a good shop that knows what they are doing with lifted Jeeps please let me know...


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looks good progress :thumbup:

Tires came in, but the rims got delayed. Not sure what the deal is, but I’m sure I’ll see them tomorrow sometime.

Did some shop cleanup, organized leftover/spare parts from the donor XJ. Got the bad motor loaded up into the rear of the donor....gonna call the junker to come and get it....


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Just as I clicked “Reply” I see the UPS truck roll up...lol.

Rims are here....


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Great build. Love the detail

Looking good. Sounds like you had the same experience with the leaf bolts as I recall having (read: major pain to get out).

Have any pics of those rear frame bumper tie-ins before they went into the frame?

Thanks guys, it’s been a lot of work but a ton of fun!

Rob Mayercik said:

Looking good. Sounds like you had the same experience with the leaf bolts as I recall having (read: major pain to get out).

Have any pics of those rear frame bumper tie-ins before they went into the frame?

Click to expand...

Yeah, those bolts were a MAJOR PITA!!!

I edited a pic I took of my bench, the tie-ins were sitting on the bench in the pic. I painted them before bolting them up.






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Went and got the tires today, pulled all the rims out of the boxes and inspected them. Everything looks good. Now I’m waiting for the Hack and Tap kit to ship. Been almost a week since ordering....still haven’t got a ship notification.



So going along with the rest of the project, I figured I look into a “simple” issue, like the third brake light not working



Got that cleaned up, connections repaired, and put it all back together. Everything works as it should now.




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Spent the day in the shop working on the XJ. I will say right up from that I’m not a body work guy.

Having said that, I finally bit off the needed trimming/cutting/folding....





I also pulled the trigger on one of those eBay DIY rear bumper kits. I’m going to fab my own swing out spare carrier.

Headed out ice fishing tomorrow....no work on the Jeep till later in the week.


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