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1996 XJ Clean DD Build

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Old 02-24-2020 | 08:06 PM
  #196  
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From: MO
Year: 1996
Model: Cherokee (XJ)
Engine: 4.0
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I spent last week working on the Mazda, replaced the damaged control arm and sway bar end link. Waiting for two tiny lock washers that won't be here for 2 weeks.

Yesterday I painted my oil pan and today I finally got it back on! And it was just as bad as I expected.
Next, I need to touch up the pan where it got scratched because it'll bother me if I don't and then prime the engine and hopefully it doesn't leak. In which case I'll be removing the axle.
About priming the engine, is that something I can do by just removing the fuel pump relay and/or ignition coil? Or do I have to remove the distributor cap?
Old 02-24-2020 | 08:42 PM
  #197  
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I can't upload pictures, I'll try again tomorrow.
Old 02-25-2020 | 11:05 AM
  #198  
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Year: 1996
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Last edited by Spencer_P; 02-25-2020 at 11:09 AM.
Old 02-27-2020 | 12:10 PM
  #199  
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From: MO
Year: 1996
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I'm really eager to rebuild the front suspension but I keep buying cars... Hopefully in the next week or so I'll have a whole week to devote to the Jeep so I can start getting it some sunlight.
Old 03-05-2020 | 06:37 PM
  #200  
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Cleaned the starter while it was out and put it back in. Got the sway bar bolted back up. Tomorrow I'm doing some work on my sister's friend's Wrangler then back to work.



Old 03-10-2020 | 03:59 PM
  #201  
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From: MO
Year: 1996
Model: Cherokee (XJ)
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Filled the engine up with oil, installed new oil pressure sender and coolant temp sender. I kinda broke the temp sender and I'm not certain it's threaded all the way but it's in a bit of an inconvenient spot so hopefully it works...

Parts to be ordered soon(coming months):
Sway bar end links
Sway bar bushings
ZJ tie rod
Steering stabilizer
Ball joints
Control arms/bushings
Rear leaf springs (Crown HD)
Front springs (TBD, Crown HD?)
Shocks (TBD)

I start my steering and suspension class after spring break so I'd like to start ordering stuff so I can get it put on while I have access to a lift and then I can spend the summer driving it and swapping to 4wd, but I also don't want to add to my shelf of parts that the warranty has expired on and is just collecting dust.

You guys have been hearing it since I started this thread but I'm really excited to start driving the Jeep as some nice weather starts coming in. Time sucks.
Old 03-10-2020 | 07:52 PM
  #202  
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From: South Georgia
Year: 1996
Model: Cherokee(XJ)
Engine: 4.0l
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I felt the same way when I was working on my XJ. I bought it in 2014 with 103K miles, it is 2020 and ut only has 104k miles on it. That's right I have only driven it 1k miles in six years. I just finished adding everything I had ordered for it through the years, now I just drive it and troubleshoot any issues. If I were you I would save my money and order all the parts you want about 2 weeks before you want to install them because you will change your mind like 15k times on what you want for your XJ. I preordered everything I needed and then I was stuck when I wanted to change something.
Old 03-10-2020 | 08:09 PM
  #203  
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I've put about 600 miles on mine since I bought it in August 2017. Congrats on getting yours driveable.

I'll probably hold off on the leaf springs and front springs, at least, until Quadratec has a sale.

Last edited by Spencer_P; 03-10-2020 at 08:11 PM.
Old 03-21-2020 | 04:13 PM
  #204  
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Old 03-21-2020 | 04:20 PM
  #205  
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Year: 1996
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Its been 2 years today since I pulled my carpet out and I've yet to get it back in. Despite school being canceled until April 6th I've only spent one day in the garage this week because my dog has stitches and can't be left alone. The garage is due for a good cleaning after the RMS, work on the Mazda, and side jobs.
I've got to prime the engine by pulling the fuel pump relay and unplugging the CPS.
Then paint and seam seal the "fresh" metal on the underside.
I'm only gonna paint the "fresh" metal so I can get it back on the road as soon as possible, then when I've got the axles out of the way the whole underside will get cleaned up.
Old 03-25-2020 | 09:09 PM
  #206  
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Year: 1996
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Cleaned up the garage and got all the oily cardboard off the ground, sanded the passenger side floors, started cleaning up the passenger underside. More rust. I hate rust. Passenger floor is ready for paint, I have to sand drivers side and cargo area. I hate to say it but some of these holes are just gonna have to get patched the best I can with some metal and seam sealer until I take up welding and can do it correctly myself. I didn't get a chance to get seam sealer or brake cleaner before this whole shut down thing so. I also grabbed a couple pictures of the fuel filter mess while I was under the Jeep. Okay photo dump.





















Last edited by Spencer_P; 03-25-2020 at 09:36 PM.
Old 03-27-2020 | 09:00 PM
  #207  
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I started the Jeep today for the first time since the rms. First time this year I guess.

Pulled out the grinder which worked great to remove the old undercoating but I had to call it quits after getting multiple eyefuls of rust, safety glasses didn't help. I'd love to go grab a face shield...
Old 03-29-2020 | 09:10 PM
  #208  
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Grabbed some stuff off the parts Jeep today. hood latch for my spare hood, u-nuts for the front bumper because I'm missing a few, and the battery to exchange for an AutoZone gift card. I also learned that the pcm has been replaced. Also for whatever reason on my Jeep the oil filter adapter is angled towards the engine and causes problems with fitting new oil filters, so I looked at the parts Jeep filter and it comes out at a much better angle than mine... so something has to change. The hatch door panel seems to be in better shape than mine thankfully, so that'll be getting swapped to mine eventually.






Looking back at the service history this is what was also done when the pcm was replaced.


Last edited by Spencer_P; 03-29-2020 at 09:33 PM.
Old 03-30-2020 | 12:42 AM
  #209  
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Year: 1996
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I also got some goodies that belonged to my great grandpa. Crazy to think they haven’t been touched in over 20 years.
Old 04-13-2020 | 07:30 PM
  #210  
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Year: 1996
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Heres where I'm at now. I need to get into the tighter spots and then it'll be ready for paint.









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