Entire 1999 swap to a 1990 XJ-long read

BIGSLVRXJ

NAXJA Forum User
Location
Des Moines, Iowa
Well as some of you know I have been off and on planning this. And then those of you that are on ComancheClub know that I've gotten more serious. Got some encouraging words from 1999MJ, gathered all the parts, and decided to tear in today. While I do consider this thread more of a personal record of my achievement, I encourage everyone to check back frequently, and I hope I can be of help to some of you that are thinking of doing part or all of this yourself.
So here's a little background on the Jeep going under the wrench, and some reasons I'm doing what I'm doing...
First off, this is my baby. It has been since the day my family bought it in 1995, it was 5 years old and 150,000 miles young. I was 7 years old then. For some reason I've just always loved the damn thing, even when I was really little. When I turned 14, my Dad knew I loved it so much, he gave it to me.
This is what it looked like...
1990JeepPioneer.jpg

I've driven it daily for about four and half years, and for the first about 2.5 years it was really good to me, no real problems. I've been through an engine and a tranny since then. I had the AW4 rebuilt, which was a huge mistake, and last summer I put in an 87 Renix engine with a 1999+ intake. Since then it hasn't run right. It does have quite a bit of power, but it backfires something fierce. I've had many people say to me "it's just an XJ, why go to all that trouble swapping the newer dash in when you can just buy a new one". Well I now have a 1999 as well that I can drive daily and not worry about the same problems I ran into in the 1990. I plan to have my 1990 around for a long time, simply because it was my first love, so I want to update it. I know it's just an XJ, but it has been here for me for the first 4 years of my driving age, and I just want to better it.

The gains...
I hope to come out of this with a functioning, running, driving, dependable Jeep. Not only that, but it will have pw, pl, pm, airbags. The donor didn't have cruise, but I'm going to try and return the non cruise column and get one with cruise, so I have that too. Not to mention that it should be quieter, because it seems like all 97+ are quieter, I think partially from the thicker dash. Forgot to mention, I have a 1999 OHC in there already that only has compass, temp, and timer because the 1990 doesn't have the brains for fuel economy, etc.

The worries...
It is a LOT of friggin wiring and I don't really have a great know how of it. I know how to run a multimeter and trace circuits somewhat, but I'm relying more of everything just working when I lay it in place.

I don't have a welder, and one is needed to weld the new column bracket support in place. I may try to just bolt it through the firewall if that is an applicable way. I may not be able to get around to the other side though.

The Jeep was rolled over, so I don't know whether the engine sustained damage or not, I'm sure hoping it didn't though.

Anyway, enough jibber jabber here's the specs...
1990 Jeep Cherokee Pioneer with 229,000 miles (manual locks, windows, mirrors)-already has open cooling system, 1999 intake, header panel, fenders, OHC, etc.
4.0-backfires like a sombitch, thinking distributor since all sensors have been replaced
AW4 (had to have original one rebuilt, crapped out a year later) now have another one in that is still good but can't keep it with the 1999 dash and such.
NP-231
Rusty floorboards-when I have this thing apart I plan to Por-15 the entire underside and probably inside too. I was thinking that'd be easier with the tranny and dash out, that way I can go all the way up the firewall.
Cracked dash panel, wiring hanging everywhere underneath, fusebox has been on fire and cobbled back together.

The donor Jeep...
1999 XJ Sport with 80,000 miles (power windows, power locks, power mirrors)
4.0
AW4
NV-231
Dash is in perfect shape, airbags didn't deploy, wiring harness is also good.

Here's the before pics...
InitialRipInandProgress6.jpg

InitialRipInandProgress7.jpg

InitialRipInandProgress1.jpg

InitialRipInandProgress3.jpg

InitialRipInandProgress4.jpg


And here's where I got after only about an hour and a half of work...
InitialRipInandProgress12.jpg

InitialRipInandProgress14.jpg


Anyway, like I said, everyone feel free to comment or ask questions...
 
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I'm confused, what exactly are you swapping, why does the 99 black XJ have a pre97 dash and no pass. side airbag, but post99 door panels in the Before Pics?
 
Okay, should've explained this better. There are no pictures of the 1999 donor in there, because I got all this stuff from a junkyard. That is all my 1990, the silver was what my Jeep looked like 4 years ago. It is black now, and has a 97+ header panel, front doors, etc. Hope that cleared up some of the confusion.
 
i loike those seats did you have them reupholstered(sp) or are they factory
 
DansGreyMj said:
i loike those seats did you have them reupholstered(sp) or are they factory
Thanks, they were actually reupholstered from www.nwautoleather.com. I had to send them my old covers and they dissected them and made me new. It was $800 when it was all said and done though. I think it was worth it, but most people don't.
 
Well on Friday I got the whole instrument panel/dash whatever they call it pulled out. I've had to work since then so nothing else got done. Here's a picture of the dash out though...
JeepDashless001.jpg

Hoping to get the engine/transmission/tcase out tomorrow with any luck. We'll just have to see how ambitious I am in the 90 degree heat/humidity. Good news is I don't have E-12s anymore, so atleast that's one less struggle. Thinking I may just pull them as a one piece assembly though.
 
bizkit642 said:
Very cool man, stay motivated and you will get it done before ya know it.

-Andrew
Yeah motivation is always my problem. The good thing is now (unlike the past) this isn't my only vehicle, so it's not a huge stress to get it done, yet I still really want to see how it turns out.
 
hey just curious how hard was it to get the dash out? my new jeep has a cracked dash and i was wondering how much time/work it was to pull it out (since you seam to know lol)
 
90XJay said:
hey just curious how hard was it to get the dash out? my new jeep has a cracked dash and i was wondering how much time/work it was to pull it out (since you seam to know lol)
It's really not too bad, this is a job I've always really not minded, but everyone else hates. It's really tedious, but I pulled the whole thing in about 3 hours. I've pulled 96- and 97+ dashes (obviously, since this is what this thread is about) and they both took me about the same amount of time. On the 96- it's like 6 bolts along the windshield, 2 behind the kickpanels and unless I'm spacing right now, that's it. If I ever have a cracked dash again that really bothers me like this one did, I will definitely replace it right away. The only thing that bothers me is the wiring that's clipped up to the back of the dash. I've heard those clip things are very hard to find after you break them. So if for example you get the dash out of a donor Jeep that has incompatible wiring with yours, be careful with the clips.
ManBearPig said:
Holy Shit!!! You sucked that bitch dry. Nice yob
Hahaha yeah, that's the goal. Just hope it keeps going this smooth.
 
1999mj said:
glad to see your finally getting started on this. Keep up the good work and keep the updates coming
For sure dude, remember to keep checking back here...I figured I'd wait til it was a done deal to put it on CC. Thanks again for the inspiration.
 
Well I got the engine/transmission/transfer case out today. Pulled them as an assembly (or tried anyway). I don't think it's easier that way like most people claim or I atleast wasn't positioning the chains right for it. I started pulling it and before I knew it I had a vertical engine/trans/tcase that wouldn't clear the front crossmember even with the hoist fully raised. Anyway, finally ended up just taking the transfer case off and lifting the transmission up over the crossmember by my strength (with the hoist's help obviously). When it goes back in, the engine will go first and I will just join the tranny/tcase up from underneath. Anyway these pictures are becoming more popular it seems, so I figured I'd take one too. This is the first Jeep powered by Collin power.
Collin-Engine1.jpg

More progress to come hopefully tomorrow. I really need to buy a welder before I can get too much further though.
 
Man this is perfect. I'm currently doing almost the exact same thing. I'm putting a 1999 4.0, aw4, np231, 81k miles, perfect interior that was rolled (airbags didn't deploy). I'm putting the entire interior, engine, tranny, transfer case, and front axle (since it's the non-disco 30). The project XJ is a 91 black with a 6.5" rusty lift on it, locked 44 rear, and nice body. I've got a total of $1400 into it so far. I've got the 99 stripped down waiting to pull the engine, tranny, transfer case. Starting to pull the 91 apart and then I'll start peicing it together. I've had them for a few weeks now and I've still got some momentum going. I'll probably be sending you some pms asking you how you tackled things. The dash is the only part that looks like it could be a problem. Though it shouldn't be too bad. How are you planning on doing the steering column mount and dash mounts? You said your talking to a guy who's done the dash swap before? What were some of the problems he ran into? I'm glad to see someone else will be doing this swap. I was starting to think maybe I'm just stupid for doing it:rof: .
 
coastie124 said:
Man this is perfect. I'm currently doing almost the exact same thing. I'm putting a 1999 4.0, aw4, np231, 81k miles, perfect interior that was rolled (airbags didn't deploy). I'm putting the entire interior, engine, tranny, transfer case, and front axle (since it's the non-disco 30). The project XJ is a 91 black with a 6.5" rusty lift on it, locked 44 rear, and nice body. I've got a total of $1400 into it so far. I've got the 99 stripped down waiting to pull the engine, tranny, transfer case. Starting to pull the 91 apart and then I'll start peicing it together. I've had them for a few weeks now and I've still got some momentum going. I'll probably be sending you some pms asking you how you tackled things. The dash is the only part that looks like it could be a problem. Though it shouldn't be too bad. How are you planning on doing the steering column mount and dash mounts? You said your talking to a guy who's done the dash swap before? What were some of the problems he ran into? I'm glad to see someone else will be doing this swap. I was starting to think maybe I'm just stupid for doing it:rof: .
Well 1999MJ is the one who inspired me. Here's what I know so far. The actual column support itself bolts to the 4 brake booster studs, I'm thinking I can use those 4 to line it up. Then IIRC it also bolts behind the ds kick panel, so that just means drilling holes for any that aren't there now. The support for the column support (confusing isn't it?) is what I'm slightly worried about. It has about 20 spot welds in it that you have to drill out. Then you have to weld it in place in the older XJ so it lines up to bolt the actual column support to. Now money wise, you're not doing bad. I have $800 wrapped up in just this swap, and I didn't even get a front axle out of the deal, I'm still going to have a CAD front axle when it's all said and done. I imagined I was going to get criticized for doing this to an XJ and told it was a waste of time and all, but all I've had are compliments about the idea so far. Just like everyone has told me, stay motivated, you'll get er done. Feel free to pm me or post up here with questions anytime man. Good luck!
 
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