cserou
NAXJA Forum User
- Location
- Sacramento, Ca
I've been on
for a minute now, and although I own 4 XJs, I've never posted a build thread because I haven't felt like I was really doing anything that different. However, I am rebuilding my '99 2dr 5 spd into a rock crawler since I've moved out to Northern California, and the unibody is messed up anyway. Since I'm going so far off the beaten path, I decided to do a thread in hopes of inspiring others and gaining some intelligent input. Why, you may ask? Because all those toyota guys get on my nerves.
So far, I have a boosted 4cyl Cummins QSB4.5, with an SAE #3 flywheel housing
Chevy Dana 60 and 14 bolt axles
Divorced 32 spline NP205 that I'm rebuilding right now and converting to a twin stick
Chelsea PTO for said t-case and PTO winch (yeah, a diesel powered winch)
Chevy hydroboost and master cylinder
HMMWV beadlock wheels
What I intend to do is build frame rails outboard of the unibody's frame rails and add to its structural integrity by putting strategically placed square tube inside the unibody frame rails and tying it together. A cage goes without saying.
I will also need to build a seriously heavy rear bumper to help add weight to the rear.
I am going to have to run full hydraulic steering and because of the backspacing of the beadlocks, and so that I can push my front axle forward.
In order to push my front axle forward, I will have to use a coilover suspension in the front.
Instead of doing a doubler, I am going to mate up a planetary from another transfer case (probably a 203) behind my transmission as an independent underdrive unit so that I can still put my divorced 205 where I want it. This will also help offset the weight of the Cummins and winch... but not all that much.
For the rear suspension, I am leaning towards a 3/4 elliptical set up because of the inexpensive cost, but I'm open to suggestions.
The hard parts are:
Finding a manual transmission that isn't too long and a flywheel housing for the Cummins. I have a couple of ideas, but I may have to go with a 2wd and change the output shaft. I would prefer to use a hydraulic clutch so that I have one less linkage to make from scratch.
Finding a high enough flow power steering pump to run both the hydroboost and hydro steer.
Keeping it cool. The XJ doesn't offer much surface area for cooling.
Deciding what color to paint it.

So far, I have a boosted 4cyl Cummins QSB4.5, with an SAE #3 flywheel housing
Chevy Dana 60 and 14 bolt axles
Divorced 32 spline NP205 that I'm rebuilding right now and converting to a twin stick
Chelsea PTO for said t-case and PTO winch (yeah, a diesel powered winch)
Chevy hydroboost and master cylinder
HMMWV beadlock wheels
What I intend to do is build frame rails outboard of the unibody's frame rails and add to its structural integrity by putting strategically placed square tube inside the unibody frame rails and tying it together. A cage goes without saying.
I will also need to build a seriously heavy rear bumper to help add weight to the rear.
I am going to have to run full hydraulic steering and because of the backspacing of the beadlocks, and so that I can push my front axle forward.
In order to push my front axle forward, I will have to use a coilover suspension in the front.
Instead of doing a doubler, I am going to mate up a planetary from another transfer case (probably a 203) behind my transmission as an independent underdrive unit so that I can still put my divorced 205 where I want it. This will also help offset the weight of the Cummins and winch... but not all that much.
For the rear suspension, I am leaning towards a 3/4 elliptical set up because of the inexpensive cost, but I'm open to suggestions.
The hard parts are:
Finding a manual transmission that isn't too long and a flywheel housing for the Cummins. I have a couple of ideas, but I may have to go with a 2wd and change the output shaft. I would prefer to use a hydraulic clutch so that I have one less linkage to make from scratch.
Finding a high enough flow power steering pump to run both the hydroboost and hydro steer.
Keeping it cool. The XJ doesn't offer much surface area for cooling.
Deciding what color to paint it.