1999 XJ Build Thread

[cleanEG]

I started building the XJ 18 months ago after my coworker insisted that XJs would make the perfect platform for an expedition/trail rig. He was right! I've been so impressed with the capabilities of this little Jeep and have truly enjoyed building it. I dont know if it will ever end, but this is where it started:

First order of business was fixing the heater core and oil leaks. While I was at it, I replaced the AC evaporator, drier and recharged the AC. Then it was replacing the rear main seal, oil pan gaskets, valve cover gaskets, oil filter flange o-ring, etc.

 

[cleanEG]

Next up was collecting some parts:

ORFab front winch bumper
ARB fridge
RuffStuff frame stiffeners
RuffStuff front/rear diff covers (D30/8.25)
Rear JCR bumper
Trucklite LED headlights

 

[cleanEG]

I then built a rear cargo drawer system and platform to mount the ARB fridge

 

[cleanEG]

 

[cleanEG]

My battery soon died and so did my alternator so I replaced the alternator with a 160amp Durango unit. For the battery I chose the Interstate MT7 AGM battery and all new 0 guage wire and 160amp inline fuse.

 

[cleanEG]

Next on the list was the suspension. I went with the RE 4.5 superflex kit and drop brackets to keep the ride nice. I also bought an AA SYE for the 231 transfer case and once it was lifted I took measurements for a new rear drive shaft from Adam's driveshaft.

 

[cleanEG]

While I was doing the front suspension I noticed the ball joints were destroyed so I replaced all of them with Spicers and a new Timken Unit bearing on the passenger side. Also rebuilt the front driveshaft with new u-joints as well. I was also trying to modify my D30 axle shafts for full circle clips and ended up bending one of the yoke ears. Instead of sourcing a spare I decided to buy some Ten Factory chromoly axle shafts and call it a day.

 

[cleanEG]

After getting the steering knuckle grooves fixed and the jeep back together, I still needed to do a few things before making a trip out to Moab with some friends. I had to solve an overheating issue that would cause problems on the trail climbing in low gear.

After overhauling the cooling system, new fan clutch, radiator, water pump, thermostat and flushing the system I found the problem in the trans cooler. The transmission fluid was getting so hot that it would heat up the coolant in the radiator so I bypassed the radiator trans cooler and installed a B&M. It's not cold enough out here to warrant the need to warm up the fluid and I was getting tired of running hot. Needless to say, it's never had a cooling problem since!

 

[cleanEG]

Here's a shot from Moab on the Lockhart Basin trail

 

[cleanEG]

I also added a Spartan locker to the front D30 prior to the suspension lift which made a world of difference on the trail. Over Xmas I scored a Smittybuilt 9500 XRC winch for a good deal and added that to the bumper.

It wasnt long before I wanted to go with 33s and after slashing my sidewall on a recent trip it was time to do it. I opted for some Copper STT Pros in 33x12.50 15 and they've been great!

 

[cleanEG]

Next up was a set of SFR motor mounts and plates since the original mounts were falling apart.

 

[cleanEG]

I also swapped out the interior lights to LEDs to update the interior.

 

[cleanEG]

Picked up some 4.88 gears for the D30 and Chrysler 8.25. Also figured now would be the time to add an ARB rear locker and rebuild both axles with new bearings/seals.

 

[Wiser]

Great build, your Jeep is clean!

 

[Nimrod]

Looking good!

 

[Original_MudButt]

Awesome-sauce!

 

[cleanEG]

Thanks Guys! Pick N Pull had 40% off this weekend so I scored some KJ rear calipers and backing plates. I have some new rotors/pads/bearings/brake lines on order. I figure since I'm rebuilding the axle, I might as well convert it to disc brakes.

 

[Bent]

I figure since I'm rebuilding the axle, I might as well convert it to disc brakes.

Tough to find fault with that logic.

 

[cleanEG]

Tough to find fault with that logic.

Especially as I get older and don't have the time to take things apart multiple times.

Sent from my Nexus 6P using Tapatalk

 

[cleanEG]

Started rebuilding the rear axle with KJ disc brakes, ARB locker, 4.88 gears, new seals/bearings, new rotors/pads, new brake lines, new yoke.