GruntRig1776

Ok guys here's the deal. . .

I have a 1998 Burgundy Jeep Cherokee XJ, 4.0 AUTO, with stock transmission and driveline, it has a 3.5" Rough Country lift, done right to ensure proper steering and suspension handling, cut out fenders, 33x12.5R15 BF Goodwrench MT's.

I have her running, after 3 days wrenching, prior she sat for almost a year on a farm with not being used.October 2021 1st Project



**Money in as of 10-29-2021: Purchase Price of $800.00 + $670.00(Electrical and Fuel Parts) + Crossmember($158) + Frame Re-enforcement Kit($605) = $2,233.00





**Engine Block Ground, Dip Stick Ground, Braided Strap Ground at Firewall, Ground near Computers.**



**As Bought on 10-05-2021**

**LED Headlights

**33x12.5R15 BF GOODWRENCH MT’s

**3.5 Inch Suspension Lift

Repair/To Do:

**Tear ALL the carpet out.**

**Degrease ENTIRE ENGINE BAY.**

**Bed line the ENTIRE floor inside Jeep.**

**I need to flex seal the roof around doors, door jams, windows and especially the top portion near the Windshield.**



Replaced:

October 2021:

**New Alternator and Serpentine Belt.**

**Camshaft Sensor and the Female Pigtail.**

**Crankshaft Sensor.**

**Fuel Injectors EV6’s.**

**Fuel Pump.**

**Fuel Pump Relay.**

**Starter Relay.**

**ASD Relay.**

**New Battery Terminal Clamps.**

**Checked and Cleaned Grounds.**

**Replaced Starter Wire to Battery.**

**New Spark Plugs and Spark Plug Wires**

**Distributor Cap and Rotor**

**New Thermostat Housing**

**New Thermostat**

**New Thermostat Gasket**

**New Upper and Lower Radiator Hoses**

**New PCV Valves (Orifice Type)**

**New Radiator Cap**

**New Valve Cover Gasket


HERES THE KICKER,

Everything on her is good, except the body it's rusted to death, with no repair option(in my opinion).

It's ****ing dumb too lol, I ordered $600 rock sliders and the unibody reinforcement kit($550), and a new transfer case support($200), and everything else mechanical(thank god most of the parts otherwise I haven't installed yet), to make her on stoppable and a damn tank to then find out after taking the carpet out that there's no floor.

I literally want to make a forever family overlanding, hunting, fishing, camping, mud rig to pass down to my kids when they get older.

Three boys, two girls, to nine-year-olds, a seven year old, five year old and a one year old. The 3 oldest work on it already with me constantly lol.

Yeah the last guy patched the floor, but not properly and it literally dissolved the floor and door jams, rockers and fender walls.

I just wanna pull the driveline engine and transmission and any other mechanical usable parts, put them with the parts that I haven't installed yet and build a ****ing monster.

Thoughts, comments, recommendation's, and idea's? I'm in Minnesota and am looking at few rollers in the country to start the new project, but before I buy, and trailer across the Nation, I really feel more comfortable confided in this Family first.

Best Regards,

Aaron D. 33-Years Old
US Army Infantry
Minnesota

GruntRig1776

I have around $3,000 into a rig that without the rust would be valued at $4,500 all day. I don't want to continue on this Rig if I'm better off swapping to a new but similar platform(92-01 year range).

RocketMouse

Can you provide some good pics of the rust areas that you are concerned with?

If it's truly in poor condition... you may want to transfer what you have on this one to one that has a better body... As our XJ's are a kind of Uni-body construction and not the older traditional body on frame construction. Rust is a very big concern to keep in check on them.

Dave51

Replace the pans. Since they'll be covered by carpet they don't need to be flawless. Besides, that's what right angle grinders are for.

https://raybuck.com/product-category...model=cherokee

You could do this with a 120 amp wire feed welder.

Jeepwalker

What's rusty? How bad. Being from Mn I can guess it could be somewhere between not-so-bad underneath to completely gone.

If it's just floors, rockers or exterior panels, they can be replaced. It's different than the spring perches barely hanging on. Mine is getting to the point where I'm going to re-weld up new spring perches. You could always head over to the Dakotas and buy a cheap (solid) 'builder' and swap your parts over....

Pictures?

robsjeep

floors you say are shot. You say the roof is rusted to the point of needing sealer, evidently to fill the rust thru holes.

Any vehicle that has as much rust as you have described will have other rust areas, that is a given. I suspect the frame is likely very rotted out, To put money into this as a keeper vehicle is foolish in my humble opinion. Unless you cut the rust out, it will very likely come back, even if flex sealed, even if treated with one of those rust converters.

A non rusty xj with a good lift, frame stiffeners, properly set up with big tires and other 4x4 goodies might fetch 10 to 15 grand. However if rusted out body is present that value drops by half or more, it basically becomes a parts vehicle.

Make sure your diffs are geared properly for your big tires, if they are, then you will want to swap them into your new body.

Stock clean xjs with a dead engine or tranny often end up at the wrecker, find a no rust one for cheap and start with that as your base.

There is an old biblical proverb about how a fool builds his house on soft sand, and the wise guy builds his house on firm rock. This principle applies to your jeep.

robsjeep

ps. when you swap over emmisions related parts, be aware of rules allowing swapping between different year models for registration, smog test puposes. In some areas, you may not be allowed to put 1998 emissions parts in a 2001 vehicle for instance. The emissions related items may not only include the exhaust system, but also even the fuel tank, the engine management system or computer, aircleaner, obd ports, dash warning lights, etc..... So think it through logically and promptly forget it all, and instead consult your state and local laws, it wont make logical sense, but it is the way it has to be done legally in some areas.

BruceB

A Jeep barely alive. Gentlemen, we can rebuild it. We have the technology. We have the capability to build the world's first bionic Jeep. Cherokee will be that Jeep. Better than it was before. Better, stronger, faster.

TrailerTrash

Take everything good from it and scrap the rest. Then find a vehicle worthy of the work you are willing to put into this rust bucket.

GruntRig1776

I've already invested $2,000 after the purchase price, welding is going to be another $2,000, so that would put me at $4,000 and that's still without fixing leaks in the roof, fixing the rockers, door jams and new fenders(front, rear and inner and outer), as well as with new insulation.

I'd really love to pull the axels, rebuild them, pull the transmission and rebuild it, same with the motor(add in solid performance upgrades), and lastly do the same with the transfer case, pull the lift, and salvage anything usable from the rest of it, and scrap the remaining.

I really just want to make the best choice in the long run, if that means taking 2+ years to properly locate, buy and build the proper Jeep, so be it, doing it right from the start without cutting corners, is going to have the end result of an outstanding Overlanding Family Rig.

I don't care where it is, if anyone knows of a rust free roller even, I will drive to it, pick it up and bring her back to Minnesota, Craigslist is ok, but I bet you all and other's have some off the books resources haha, or it may just be my wishful hoping and thinking.

robsjeep

Yes, your rusted XJ can be rebuilt, Six Million Dollars later it will be rebuilt.

Sirsyc0

Keep in mind that a 2wd will work to. That might open up a few more doors for you.

robsjeep

https://row52.com/Search/?YMMorVin=Y...e&Distance=500

looks like currently there are 32 xjs within 500 miles of me, and consider than about ten miles on one side of me is ocean. keep your eyes peeled, also check out of area Craigs list in non salted road areas that you will be willing to travel too. If a good one shows up for sale at a great price, it will get snapped up quick, so you got to look frequently dedicate spending 10 or 15 minutes per day searching craigslist and wreckers websites, avoid rust prone areas that salt the roads as likely any xj sold from there will be rusty.
eventually you will be the first caller on some cherry body xj, that maybe has a blown tranny or engine, but has nice paint, and interior, rust and accident free, and at a real good price, within your desired driving range for pickup.
so find resources on the net and look every day, maybe even twice a day, you got to be first to respond if you want to score the great deal, good paint is important, as a repaint can cost thousands, and so is a nice interior, unless you have a good interior already for swapping. But dead motor, or tranny , or brakes, bald tires, etc...or such, no problem for you, you want the best body for little money, so search on! also note that you can recoupe costs by parting any unused or duplicate parts from both bodies. you will have a pair of axles extra, keep the ones geared for your tires!, you may have a good or at least a core of tranny, Xfer case and motor, all kinds of spare sensors, the computer, etc.. which may earn you a few bucks selling them. Of course if you are in a remote area, selling them might be difficult do to the high freight cost of you shipping a tranny or axle to a buyer.

GruntRig1776

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GruntRig1776

I guess you'll have to elaborate for me Sir. Not afraid of a challenge, the more successful I'll feel!