2001 Jeep XJ build

[gummybear]

Hey guys, so I am starting my 97 XJ build today. I have owned this jeep for about 8 years now. I haven't done much with it since life has gotten in the way, deployments, moving, job etc but now I am selling my 2016 chevy Colorado to save some money. I am planning on using my Jeep as a daily driver as well as my adventure vehicle. I am planning on doing this as low cost and DIY as possible and I will be looking to you guys for inspiration and help along the way. I live not too far from Built By Fluffy so hopefully I will be spending some time with him and his wife while we work on our projects together!

 

[gummybear]

So today was a busy day, I took all 5 wheels off and had the tires removed from the rims. She is now sitting on jack stands. the next goal is to prep and paint the rims with paint I have already, and while I have the tires off I am going to check the breaks and lines and note any leaks that ill have to take care of when I replace the suspension. Anyone have any tips for painting the rims or things I should check

 

[renodemona]

Hey nice XJ! I see you're down in G-ville, have you made it up for any of the Reno Overlanding group's events? They meet 2nd Wed of each month at Famous Dave's BBQ.

 

[gummybear]

Hey nice XJ! I see you're down in G-ville, have you made it up for any of the Reno Overlanding group's events? They meet 2nd Wed of each month at Famous Dave's BBQ.

Thanks brother. No I haven't, I just got into all of this to be honest with you. I've been off roading and camping out of my rig for a while but I haven't had my rig up and running in years. I have just gotten back into it, if that's an invite though id love to check it out

 

[renodemona]

Thanks brother. No I haven't, I just got into all of this to be honest with you. I've been off roading and camping out of my rig for a while but I haven't had my rig up and running in years. I have just gotten back into it, if that's an invite though id love to check it out

Yup definitely an invite! I know the pain of real life keeping me away from adventures so glad you are able to get back to it. I'll be at the meeting in Sept after rebuilding the fuel system for like the 4th time.

 

[renodemona]

I've seen lots of people use that plasti dip spray paint but you have to clean the surface pretty good or it doesn't stick well. I'm not too knowledgeable on the XJs but generally I'd say replace the wearable parts since you got the wheels out of the way. Never hurts to replace the fluid either. I don't know if that year is new enough to have the wheel spin sensors? I know on some of the Liberty's they go out all the time and make the traction control not work right. What tires you looking at, or just off to paint the rims?

 

[Dustinfromohio]

You’ll want to wash the rims really well with soap/water then wipe them down with acetone/rubbing alcohol and make sure they are completely dry before painting. While painting you want to spray them with the paint can horizontal, not down from above. That will give you a more even coat and eliminate the can dripping on the wheels. Nice ride! I’ve always had a thing for the XJs

 

[KonzaLander]

Nice XJ! Whatever you do, don't paint the Turbines black. Those wheels would look great in a gunmetal or dark bronze.

Parts I would suggest carefully inspecting/replacing. Front: Pads, caliper, rotor, wheel bearing, ball joints, axle shaft u-joint, tierod end, control arm bushings, trackbar and trackbar bracket. Rear: Pads, rotor, wheel cylinder, bump stop, leaf bushing, shackle bushing, shackle.

 

[gummybear]

You’ll want to wash the rims really well with soap/water then wipe them down with acetone/rubbing alcohol and make sure they are completely dry before painting. While painting you want to spray them with the paint can horizontal, not down from above. That will give you a more even coat and eliminate the can dripping on the wheels. Nice ride! I’ve always had a thing for the XJs

Thanks, and yeah I personally have always loved the xj since I was a kid.

 

[gummybear]

Nice XJ! Whatever you do, don't paint the Turbines black. Those wheels would look great in a gunmetal or dark bronze.

Parts I would suggest carefully inspecting/replacing. Front: Pads, caliper, rotor, wheel bearing, ball joints, axle shaft u-joint, tierod end, control arm bushings, trackbar and trackbar bracket. Rear: Pads, rotor, wheel cylinder, bump stop, leaf bushing, shackle bushing, shackle.

Thanks for the list, I've started checking most of that but its nice to have a second set of eyes on the list of things to check just too make sure I don't forget anything

 

[Motoboss]

It's great your starting to rehab the XJ. Way too many folks have turned the XJ into off road warriors thus trashing them and the numbers are dwindling. A few suggestions;
DO NOT put some giant lift under it. Way to much stress and parts replacement.
DO NOT put giant tires on it. Too much stress on the stock unibody for daily driver
DO upgrade the shocks, break lines and replace all hoses

If you're going to use it as a daily driver a 3 inch lift, with shocks, springs (leaf pack and front) works extremely well with 31 inch tires.

Check and repair rusty floors and panels. Rust kills these thin body SUVs.
Think mechanical first. Anything that effects safety, drivability and reliability should be addressed first.

Be prepared for the unexpected. Repairing a rusty rocker can turn into a can of worms!

 

[gummybear]

It's great your starting to rehab the XJ. Way too many folks have turned the XJ into off road warriors thus trashing them and the numbers are dwindling. A few suggestions;
DO NOT put some giant lift under it. Way to much stress and parts replacement.
DO NOT put giant tires on it. Too much stress on the stock unibody for daily driver
DO upgrade the shocks, break lines and replace all hoses

If you're going to use it as a daily driver a 3 inch lift, with shocks, springs (leaf pack and front) works extremely well with 31 inch tires.

Check and repair rusty floors and panels. Rust kills these thin body SUVs.
Think mechanical first. Anything that effects safety, drivability and reliability should be addressed first.

Be prepared for the unexpected. Repairing a rusty rocker can turn into a can of worms!

thanks for the advice, I just bought 31's yesterday and I was thinking the exact same thing with the lift. honestly I'm not looking to turn this into a king of the hammers champion, just a capable off road overland vehicle

 

[gummybear]

It's great your starting to rehab the XJ. Way too many folks have turned the XJ into off road warriors thus trashing them and the numbers are dwindling. A few suggestions;
DO NOT put some giant lift under it. Way to much stress and parts replacement.
DO NOT put giant tires on it. Too much stress on the stock unibody for daily driver
DO upgrade the shocks, break lines and replace all hoses

If you're going to use it as a daily driver a 3 inch lift, with shocks, springs (leaf pack and front) works extremely well with 31 inch tires.

Check and repair rusty floors and panels. Rust kills these thin body SUVs.
Think mechanical first. Anything that effects safety, drivability and reliability should be addressed first.

Be prepared for the unexpected. Repairing a rusty rocker can turn into a can of worms!

I'm having difficulty trying to fine the right suspension lift for it though. I see some have 3" up front and 2" in the back and others are 3' front and rear. if I want it level which oe should I go with?

 

[GoneJeepin]

On the lift if I remember right it depends on which rear axle you have. Some have the Mopar 8 1/4” some gave a Dana 44.
We are going with a Rubicon Express 3” on our 96.

 

[Prerunner1982]

Welcome, nice XJ.
As far as the wheels... I think leaving the spokes and the lip brushed and painting the area between the spokes might look good.
And something I don't say to guys too often...."Nice rack".

 

[gummybear]

On the lift if I remember right it depends on which rear axle you have. Some have the Mopar 8 1/4” some gave a Dana 44.
We are going with a Rubicon Express 3” on our 96.

Yeah I have a Mopar 8.25 rear I was thinking the same thing but if it’s two different axels then I was thinking I’ll have to do 2” up front and 3” in the rear

 

[Prerunner1982]

if I want it level which oe should I go with?

Think about the gear you may be hauling around, unloaded a little rake (high in the rear) wouldn't be a bad thing so that it sits more level when loaded with friends and/gear or hauling a trailer instead of dragging ass.

 

[gummybear]

Think about the gear you may be hauling around, unloaded a little rake (high in the rear) wouldn't be a bad thing so that it sits more level when loaded with friends and/gear or hauling a trailer instead of dragging ass.

I didn't really think about that actually, thanks that makes sense

 

[Motoboss]

I'm having difficulty trying to fine the right suspension lift for it though. I see some have 3" up front and 2" in the back and others are 3' front and rear. if I want it level which oe should I go with?

On the lift I went with the Rough Country 3 inch. It came with shocks, springs, short arms and rear leaf pack. I did replace the shocks with Bilstiens 5100 as the RCs sucked.

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[gummybear]

So quick update. I have started inspecting the undercarriage and I’m going to have to do a lot of work to get this thing on the road. The front and rear breaks are in super rough shape, the tie rod end boots are all shot, and the shocks are fried. Pretty much the only good things left on the undercarriage is the leaf springs. I’ve also noticed a leak coming from what appears to be my rear main so that’s exciting. I ordered new tires, super cheap from Walmart. So those should be in by Tuesday. I also notice that the hose connecting the air box to the throttle body is somehow missing so I need to find a replacement for that but it looks like I’ll have to buy a whole new intake system for that since I can’t find just the hose anywhere except for eBay for like $50. I’ve also noticed the rear diff has a class 1 leak coming from the the diff cover and the front of the t case. The diff cover I’m not so concerned with since I have to change all of the fluid anyways and I will be changing the gasket when I do that but the t case have me slightly concerned. I have a few pictures but will post them and the rest of the pictures when I get home tonight