A few years ago, I documented the build of this Jeep.
https://grassrootsmotorsports.com/forum/build-projects-and-project-cars/the-cherokee-affair/143386/page1/
I fixed up a 2000 Jeep Cherokee for my son while he was in school. He used it at school and issues starting it. After a new battery and a starter replacement(requiring me to drive 9 hours to perform), we finally determined it was a failing Neutral Safety Switch. This was replaced easily.
However, this episode lead my wife to declare the Jeep was not reliable enough for him 4 hours away from home. The air conditioning also failed. It needed a few more things too.
So the vehicle landed back in my driveway and I drove it instead. I slowly began improving things.....
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Pulled dashboard, and replaced heater core/AC/blower motor.
Replaced front carpeting. I found someone on FB who bought new carpeting and never installed it. Got it for half price-my brother picked it up on his travels so shipping was free.
Replaced the thermostat - which really improved cold weather driving.....
Replaced injectors after one injector fried about a mile from home.....
Put in LED reverse light bulbs. Factory ones were pitiful.
Welded in a new driver's side rocker panel. - Rust worm....
It did Jeep things.....
Then I found someone selling an unused Rusty's 4.5" lift kit on FB. $300 off the regular price and no shipping....
Hmmmm.
So things escalated. I took my time with the install.
I used ALOT of heat to get the leaf spring bolts out. It worked. I replaced all the hardware.
Built extended bump stops.
Replaced the steering with new ZJ V8 stuff...
The drop link bolt was a pain. I had to pull of the bracket and used mucho heat and got it out. NEw hardware installed.
I painted everything with Rustoleum Black..... even the new stuff.
I found a set of Wrangler 16x8 wheels on FB for $140. Deal.
I swapped the Slip Yoke for a new driveshaft. I took apart the transfer case and had a friend machine the output shaft on a lathe. Rebuilt the case with new seals and clips. More heat and welding needed for the frozen drain plug, but I was successful in saving the case.
New u-joints in the front shaft. New u-joints for used JY rear driveshaft, but cracked the yoke. So I had to get a new one made to perfect length. Price on ebay was fair.
So yesterday, I got new BFG's..... Memorial Day rebate!
265/75R16 AT KO
It will become the cabin toy, snowboarding and hunting hauler.....It's fun to drive.
I still have a few more projects.....
- Oil Pan gasket and Rear Mail Seal
- Passenger side Rocker Panel weld up and paint.
- Air Bag light is on....
- Paint the door trim black
- Maybe a DIY front bumper weld up kit
amerson
New Reader
5/26/21 10:30 p.m.
Those wrangler wheels look good.
Replacing the front and rear bumpers is definitely a nice idea.
Jeep XJ's are indeed fun. My 1999 is my go to daily, mild lift, bigger tires. At 230,000 miles, still runs good. Just basic maintenance. Also acquired a 2000 XJ. Crash victim. 130,000 miles, runs strong. Already had a lift, new big tires, and whole lot of new maintenance parts. Slowly making it into a woods truck.
Looking good.
I'm kind of partial to them myself.
This is the DIY weld-up winch bumper from Amazon.
Nice. I got a 86 XJ I'm currently working on, 2.5 with the 5 spd. Its my 3rd cherokee so I'll be following your build.
A friend just sent me a current picture of his topless Cherokee build. He's almost finished with his tool bar:
