92 2 door XJ build

NickMaul said:
You remember how much you stretched the rear axle backwards before you got close to the tank?
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It wasn't the tank that was the issue. I'm stretched 2" right now and still have plenty of room for the shocks mounted in the factory orientation. At 3" of stretch, I would have to tub the rear fenders and, at the time, didn't want all the extra work. I would also have to have a longer driveshaft made. There is still plenty of room between the tank and diff. I can take a pic this evening if you'd like.
 
NickMaul said:
You remember how much you stretched the rear axle backwards before you got close to the tank?
Click to expand...
I'm stretched 3" but did a lot of cutting in the rear before I just chopped it off a couple years ago. flipped xj springs net 5" stretch but require fuel tank modification. With my skid plate and tank I'd say no more then 3" or 4" before you come into contact with them. I used 2wd f150 springs for my mains and built my pack. MJ spring will net a 3" stretch too.
 
Been working on the jeep a lot as of lately. New rear axle is in. New traction bar is in. Shock hoops are under way. I've got until Saturday to finish everything so I can have a week to break in the new gears before Jeep Jamboree.

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Saturday was a productive day. Finished the shock mounts, painted, traction bar set, shocks installed, ebrake cables set, and started on the exhaust. I had to stop to head to Raleigh for my mother's bday. I have to return the muffler I bought since I didnt pay attention to the inlet/outlet locations. I bough an offset in/centered out instead of a centered in/offset out. I did get the rest of the exhaust welded up so all that's left is to install the muffler.

During the week, I'll be doing some finishing touches like reinstalling the carpet, double checking all nuts/bolts, trimming front fender more, and then driving to break in the rear gears. It looks like I'll most likely be changing the gear oil at URE the night before the Jamboree unless I can find time to drive a ton and then change the oil before Wednesday night.

I'll get pics at lunch today.
 
So I got a good break in this past weekend at Jeep Jamboree. List of to-do's has grown with some parts giving up on this trip.

Burned up PS pump
Steering box is leaking like crazy...again
Bent a wheel
Bent the rear anti-wrap bar
Ball joints are shot
Front locker is popping very loudly
Motor is running warmer than usual

I'll be going through everything in the coming weeks to make sure nothing else is hurting. I'm searching for steering options for the pump and box. I've also started pricing out D60 fronts. Looking at an 02 SD D60 this coming week. I'll redrill the unit bearings/rotors for 8x6.5 pattern. I've already priced it all out for swapping in/gearing/3 linking the front. It'll be costly but I should be able to recoup about half the cost selling the 44.

Here's the only pics I have from this weekend. I still have more fender trimming to do. In the last pic I have circled the bend in the antiwrap bar

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The line I had on the D60 fell through as the guy stopped responding to me. So, I think I'll just run the 44 for the remainder of the season. I've already found an XJ steering box and hope to pick it up this evening. I've also ordered a rebuild kit for the box and a new non-keyed pitman arm. I'm still trying to decide what I want to do with the rest of the steering. I may end up welding up some bracing on the stock chevy knuckle for now.

Tear down of the motor for a rear main seal and new header will begin this evening. I hope to start the tear down on the new-to-me steering box tomorrow and have it drilled and tapped by Wednesday night. I'm debating about throwing new seals in the tapped Durango box I currently have and putting it up for sale. On the other hand, it would be nice to have a spare box already tapped just in case.
 
I wish I could find the motivation you have. I really wish I could get this MJ together.......
 
That pile of parts look familiar to what I had going on a month or so ago in that same shop.

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ghost said:
I wish I could find the motivation you have. I really wish I could get this MJ together.......
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I've only wheeled once since July and I just really want to be back on the trails. Bring the MJ up to here and we'll finish it for you.

Keith Odom said:
That pile of parts look familiar to what I had going on a month or so ago in that same shop.

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Sure does. This is the first major overhaul on this motor. The header is the factory original and finally cracked back in July. I've had the parts to fix it for months now and just haven't done it. After Jeep Jamboree and the damages incurred there, I figured I'd take the whole rig back down and get everything that needs attention straightened out. I'm hoping to have it all back together before the Veterans ride. Many late nights are ahead of me. You should come down and hang with us again.
 
Hard to do with half the front disconnected. My son started the axle swap this summer then life got in the way and we've both been too overwhelmed frustrated to get back at it.
 
About time you did some basic maintenance on that thing haha. I’ve had all that stuff replaced for years. Yet I’ll still be flushing the cooling system again this weekend...


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adamk said:
Many late nights are ahead of me. You should come down and hang with us again.
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I'll try man I am really busy up here at school. But I'm still getting some good wrenching time in just helped a buddy replace his valve cover gasket because it was leaking badly. I can't wait to get to watch that thing on the trail for behind my steering wheel.

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Put in a little more wrench time last night. The Durango box has been removed and I inspected the frame for cracks. It's still nice and clean. I got the new thermostat installed and a couple of the hoses hooked up. I then started disassembling the new to me XJ box so I can drill and tap it for hydro assist. I'll end up rebuilding the Durango box and selling it most likely. I also removed the steering shaft and welded the shaft to the coupler at the the steering column. There's an overmoulded rubber bushing there that likes to dry out and crack. Once that happens, it creates slop in the steering.

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No pictures but the new box is assembled and installed. The whole right side of the motor has been reassembled. Below is the to-do list. Hopefully this week I'll get it all finished.

Replace oil pan gasket
Replace rear main seal
Fill and bleed steering
Replace heim joint at pitman arm with high angle TRE
Drain and fill rear diff (break in oil is still in there)
Replace air filter
Install harnesses
Tie B and C pillars together
 
Well I finished the jeep before the Veteran's Ride a few weeks ago. Didn't take any pictures at that ride. I did go back out to Uwharrie Saturday. My fiance drove majority of the day and we took the pups with us. She ran the front side of Daniel for the first time and did great. The dogs really like riding in the jeep and love being out in the forest.

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Bought some new (to me) wheels and tires. Got some harnesses. Wheeled Big creek.

Items now on order are:
Reid high steer knuckle
1.25” High steer arm
Hardware
Ball joints
Tie rod ends

Shopping for a rear locker but may end up with a spool just because it’s cheap and easy.
 

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Did you ever fix your anti-wrap bar? What do you think caused the failure? I have all the pieces to build mine and was planning on running my upper bar further up on the lower bar and adding some bracing.
 
YJJPWrangler said:
Did you ever fix your anti-wrap bar? What do you think caused the failure? I have all the pieces to build mine and was planning on running my upper bar further up on the lower bar and adding some bracing.
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I didn’t. Because the upper arm is adjustable, I just adjusted it so everything was happy again. I used 1.75” .120” wall for the bar. I landed pretty hard on it which caused it to bend. It’s still doing it’s job and working great.
 
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