Corky's 99 Chili Pepper Sport
#32
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Thanks !! I appreciate the encouragement.. I'm enjoying this build...
After adding the dana 30 RC differential rock guard, I was planning to get one to match the back configuration with the 8.25 Kentrol stainless cover.. And after some searching, yet again I've come to realize RC doesn't make a diff guard for the 8.25.. .. What the heck is going on with the 8.25 and the lack of goodies for this rear ?
OK I'll admit I'm a little strange when it comes to keeping certain things in check.. So my only choice was to make my own !! I bought a RC dana 35 rock guard and modified it for the 8.25...
I present the only Rough Country 8.25 differential rock guard on the planet..
After adding the dana 30 RC differential rock guard, I was planning to get one to match the back configuration with the 8.25 Kentrol stainless cover.. And after some searching, yet again I've come to realize RC doesn't make a diff guard for the 8.25.. .. What the heck is going on with the 8.25 and the lack of goodies for this rear ?
OK I'll admit I'm a little strange when it comes to keeping certain things in check.. So my only choice was to make my own !! I bought a RC dana 35 rock guard and modified it for the 8.25...
I present the only Rough Country 8.25 differential rock guard on the planet..
#33
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
So after that hurdle was jumped I recoated the 8.25 housing and got it ready for the install... Here's a pic of the Truetrac diff and 4.56 gears before closing it up.. I like the center thrust block and retainer arrangement on these..
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ijeeep (03-22-2021)
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ijeeep (03-22-2021)
#36
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
And it's installed !! I took a chance and added a 6* shim to get ready for the SYE install.. Let's hope I chose wisely..... That's a wrap for today and I'm beat...
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ijeeep (03-22-2021)
#37
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Since all the rear disc components are new I had some trouble installing the abutment clips...Only one .10 clip would fit for each pad ..So I put it on the thrust side of the pad...I'll keep an eye on it and adjust if necessary.. Other than that it went together well.. I adjusted the parking brake using the " adjust until tight then back off 4 clicks" approach and it gave me a nice range of motion..
#38
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Finished up the rear area with a freshly sandblasted and epoxy coated ZJ fuel tank skid plate...Followed with a new Curt hitch receiver...
#40
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Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Next up is the transfer case SYE...After reading all the threads on how hard it is to remove the transfer case I was prepared for the worst..But it turns out it really wasn't that bad.. Drop the crossmember,lower the transfer case,drain the fluid and unbolt the unit...I used a 14mm ratchet wrench on all the retaining nuts..Maybe it's the mileage that made it so easy {?} Anyhow here's the starting point..
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ijeeep (03-22-2021)
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ijeeep (03-22-2021)
#42
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Although I could have simply swapped out the shaft and moved on I ended up stripping down the case,cleaning all the internal and external parts, and changed out all the seals for good measure... After some thought I wanted to simplify the transfer case linkage while I was at this stage and bought Azzy's linkage kit...It's a great quality kit..
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ijeeep (03-22-2021)
#43
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
And as you've guessed if you're following the build,
I couldn't resist the temptation to shoot the transfer case halves with a VHT cast aluminum chemical resistant coating...Here's the finished product ready to install with the new advanced adapters SYE...
I couldn't resist the temptation to shoot the transfer case halves with a VHT cast aluminum chemical resistant coating...Here's the finished product ready to install with the new advanced adapters SYE...
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ijeeep (03-22-2021)
#44
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
Oh, I did install a new speedo gear...I originally bought a 39 tooth piece using one of the generic calculators I found on the site...And then I ran across another graph that takes the actual tire size {33s aren't exactly 33" depending on the brand} into account and realized I actually needed a 38 tooth gear.....Oh well, at least I caught it now.. So I indexed the housing accordingly for the 38 tooth unit..
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ijeeep (03-22-2021)
#45
Thread Starter
Senior Member
Joined: Dec 2018
Posts: 704
Likes: 374
From: Harrisburg,Pa.
Year: 1999
Model: Cherokee (XJ)
Engine: 4.0L
So as other have found I first bought an aftermarket trans mount and immediately saw what everyone warns about... The metal and rubber on the aftermarket piece isn't suitable to think this is anything but a quick fix...New factory mount on the right...And now I'm stuck with a door stop on the left for the comparison ...
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ijeeep (03-22-2021)