You can buy a reman for less than $3k so I'd personally go that route instead of having that local rebuild. Unless you don't feel comfortable swapping in the reman yourself, of course.
I've rebuilt 2 4.0s this year (88 & 00) and they were about $800 each. If you need to buy tools then it'll be...
Chiming to say I have this as well and works great. I use it with JScan (CDJ specific). Cost $20 per VIN but well worth it. They have an XJ option but I haven't tried with that yet.
Outside of your budget, but I use this one for everything else including the XJ for about $130: ThinkDiag 2
This is my 2nd rebuild and I did Cruiser's method the first time with no issues so I kept with the idea of "don't fix what ain't broke". I figure as long as you properly pre-lube then all should be good.
Swapped the oil pump and it built pressure in about 15 seconds. Fired it right up. I used a...
Yep, the connector turned out to be the culprit! Now I feel like a big dummy with that one. Looks like the solenoid-side is damaged. I'll probably convert to a ring terminal.
Now it's turning over, but I'm not seeing oil pressure after cranking (fuel relay and coil disconnected) for a minute or...
Here are some results:
I get 12v on pin 6 when 'ON'
I get 12v on pin 7 when 'START'
I get 12v to the brown wire on grey connector (c108?)
I do not get 12v from the PDC to the solenoid
I jumped 7 to the solenoid and get 12v but nothing happens
I have continuity between the blue/black wire and...
It works when I bridge the solenoid connections just fine. It's a known good starter that I took from the MJ. I'm not even getting a solenoid click, only the relay.
I just rebuilt my 2000 and can't seem to diagnose a no crank.
The starter relay is triggering when the key is turned so doesn't that rule out the NSS?
I also have a relay with the cover off that I can manually trigger and nothing is happening. Other known good relays aren't making a difference...
Hmm, I make adapters for the MJ (howeitsdone.com) but I wonder if there is a need for the XJ. I have my 2000 XJ but those kits are readily available. Should I look into 96-pre?
I'm going to run the XJ intake actually, I just realized the intake the guy gave me is the older 'log' style.
I suppose it's just a question of gasket then. I have a '99 gasket that should fit the newer intake. but the exhaust ports get blocked a bit. I think I'm going to have to trim the...