Se7en62's '97 Cherokee XJ "GROOT" Overland Build

Se7en62

Adventure Seeker
Welcome to my build thread.

My name is Stefan and I'm from Hutto, Texas, on the outskirts of Austin and this is "GROOT." I picked up this '97 XJ in Houston on Friday, 2/3/17. When I found my (1st) Jeep on Craigslist the picture (below) was used. - I think it's pretty obvious that there's a tree on the roof, hence the name "GROOT".

XJ.jpg

The PO was from WI, where the Jeep lived for 15 years. That being the case, it has it's rust, but nothing I can't stop and repair. The PO then moved to Houston, where it spent the last 2 years sitting in a garage. I bought it as-is in it's "current" state for $1,600 and with the help of a friend, towed it back to Austin.

0928af0208b3e4aaf1a6209b7bb0a093.jpg


It drives just fine, a little noisy since there isn't a muffler, but fair otherwise. Super Bowl Weekend, I drove it 150 miles round trip to a friends's BBQ in Fredericksburg. No issues other than a dead battery when I went to leave.

562113cb90568578800a479319485fcf.jpg


First on the agenda, is to get it inspected so I can go get it registered and make it a proper TX Jeep: New Battery, New Fluids, New Filters, New Brakes, New Exhaust, Alignment, New Wheels and Tires, Inspection, then Registration. In that order.

Next up will be to go through the entire undercarriage to stop the rust from spreading. Rocker panels rotted, so they're getting cut out and replaced by steel rock sliders. The carpet's getting pulled, and the entire floor and undercarriage are getting taken down to bare metal, Corrosealed, coated in POR-15, then rhino lined for insulation. I've found a couple spots where it needs some welding, but nothing major so far. As far as I can tell it's mostly surface rust. Regardless, it's all getting stopped in it's tracks.

Along the way, I hope to get the rest of my build put together as efficiently as possible, so we can hopefully be back to Ouray before the end of this year.
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***UPDATE FOR FACTORY JEEP BUILD SHEET TOOL:***
  • In case anyone else needs this resource, click HERE for to obtain a PDF of your Factory Build Sheet.
  • Then, Type your VIN into the search box and Hit ENTER.
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BEGAN AS:
1997 4.0L Sport 4x4 w/ 143k ($1,600)
Power Windows & Locks
AX15 5-Spd Manual w/ NP231 Transfer Case
Dana 30 Front / Chrysler 8.25" Rear w/ 3.07's
Old Man Emu 3.5" HD Lift
Old Man Emu Shocks
Old Man Emu Dakar Leaf Packs
JK's QD Front Sway Bar Links
Monroe Magnum Steering Damper
31"x10.5"R15 BFG M/T's on 15" Grizzlies (Sold for $350)

NECESSARY MAINTENANCE & UPGRADES: $1,883
[CHECK] 285/70R16 Firestone Destination M/T's on 16" Rubicon Wheels ($850)
[CHECK] Rough Country Wheel Spacers and Gorilla Lugs ($0)
[CHECK] Dirt Bound Battery Tray for Group 34 ($65)
[CHECK] Interstate Mega-Tron II Group 34 ($138)
[CHECK] MSD Ignition Coil and Accel Coil Adapter ($72)
[CHECK] Accel Cap and Rotor ($27)
[CHECK] Taylor Spiro-Core Pro 8mm Wires ($55)
[CHECK] Champion Copper Plus Spark Plugs (RC12LYC) ($12)
[CHECK] Upgraded CherokeeForum Headlight Harness ($18)
[CHECK] New Front/Rear Brakes (New Calipers, Rotors, Pads, Drums, Shoes, and Drum Cylinders) ($253)
[CHECK] Convert C8.25 to KJ Disc Brakes ($170)
[CHECK] LubeLocker C8.25 Diff Gasket ($22)
[CHECK] Yukon YMS5778 Pinion Seal for C8.25 ($15)
[CHECK] Timken 8516N Pinion Seal for D30 ($11)
[CHECK] Dynamax Cat-Back Exhaust ($140)
[CHECK] Welding Labor on Exhaust Install ($100)
[CHECK] RuffStuff Cure for Stock Steering ($26)
[IN-PROGRESS] WJ Sway Bar Upgrade ($26) <-----I still need to get new Grade 8 Hardware, Bushings, and Drill the Holes.
Clayton Long-Arm Kit ($650)
Cav Fab Crossover Steering System ($215)
Supreme Suspension Adjustable Track Bar ($139)
[CHECK] Alignment (FREE)
Replace OME Dakar HD Leaf Packs w/ New OME Dakar HD CS033RA Packs ($272)
[CHECK] Motor Oil - 6.0 Quarts (5.7L) Rotella T6 5w40 ($50)
[CHECK] Valve Cover Gasket ($38)
[CHECK] Oil Pan Gasket ($24)
[CHECK] Oil Pan Drain Plug ($3)
[CHECK] Replacement Oil Pan ($56)
[CHECK] Rear Main Crank Seal ($18)
[CHECK] Motorcraft FL1A ($4)
[CHECK] Transmission Fluid - 3.3 quarts (3.12L) Lucas 75w90 Synthetic Gear Oil ($65)
[CHECK] Differential Fluids
--------- Dana 35 - 3.5 Pints (1.66L) SAE 85w140 Gear Oil ($8)
--------- Chrysler 8.25 - 4.4 Pints (2.0L) SAE 85w140 Gear Oil ($9)
[CHECK] Transfer Case Fluid - 2.2 Pints (1.0L) Dexron III/Mercon ($5)
[CHECK] Replace Radiator Cap ($6)
[CHECK] Radiator Flush - 10.5 Quarts (9.9L) ($44)
[CHECK] Brake Fluid - DOT 3 High Temp. ($3)
[CHECK] Steering Fluid ($6)
'99 V8 4x4 Durango Steering Box ($150 new)
'99 Dakota Steering Pump
[CHECK] (2) Pentius PFB59161 UltraFLOW Fuel Filter ($7)
[CHECK] Replace A/C Compressor ($138)
[CHECK] Replace A/C Dryer ($21)
[CHECK] Replace A/C Evap. Coil ($62)
[CHECK] Replace A/C Heater Core ($34)
[CHECK] A/C Seal Kit, Freon, PAG Oil, and Can Valve ($60)
[CHECK] Replace Bumpstops F/R ($65)

AXLE SWAPS $175
Ford 8.8 w/ 3.73's and LSD from Explorer ($175)
[CHECK] Dana 30 w/ 3.73's from ZJ ($175)

NECESSARY BODYWORK: $352
[CHECK] Window Tint ($150)
[CHECK] Trim Front Fenders
[CHECK] Radius Cut and Fold Rear Fenders
[CHECK] Body Trim for Fender Edges ($12)
[CHECK] Cut, Tuck, Fold, and Seal Rear Quarter Panels ($20)
[CHECK] Replacement Driver's Side Passenger Latch Mechanism ($18)
[CHECK] Replacement Driver's Side Tail Light ($11)
[CHECK] Remove/Repaint Cowl Panel & Wiper Stalks ($0)
[CHECK] Bosch Clear Advantage Wipers ($35)
Monstaliner Sans Panties ($200)
[CHECK] Plastidip MOAB Wheels ($18)
[IN-PROGRESS] Rust Mitigation w/ Corroseal and Rust Bullet ($106)
  • Remove Front Carpets
  • [CHECK] Remove/Replace Cargo Carpet
  • Replace Front Floor Pans
  • [CHECK] Remove Rocker Panels
  • Replace with Steel Rock Sliders in Mini-Boatside Arrangement

INTERIOR & ELECTRONICS: $463
[CHECK] Rustoleum Bed Liner ($20)
[CHECK] ArmorAll All-Weather Floor Mats ($16)
Cover King Spacer Mesh Front & Rear Seat Covers ($120)
[CHECK] Water-Resistant Pyle Head Unit & Pioneer Speakers ($84)
[CHECK] Ellipsis 8" HD Tablet Running GAIA GPS ($55)
[CHECK] Torque Pro App ($5)
[CHECK] OBD-II Bluetooth Adapter ($13)
[CHECK] RAM Mount Tablet Mount ($65)
[CHECK] RAM Phone Mount ($45)
[CHECK] Midland 1001LWX CB Radio ($32)
[CHECK] Firestik 4' CB Antenna ($20)
[CHECK] Firestik 18' Coax Cable and Spring ($31)
[CHECK] Firestik Fender Antenna Mount ($12)
Yeasu HAM FRS Handheld
Midland GMRS Handhelds
[CHECK] SuperBrightLED's Interior LED Upgrade ($20)
[CHECK] (2) 18W 2x6 Flush-Mount LED's in Rear Hatch ($20)
[CHECK] Kidde Fire Extinguisher ($25)

ARMOR & BODY UPGRADES: $513
RuffStuff Full Unibody Stiffeners
Custom Rock Sliders w/ Mini-Boatsides
Filthy Addictions Steering Box Reinforcement
[CHECK] Rough Country Winch Bumper ($400)
[CHECK] Rough Country D-Rings ($80)
[CHECK] X-Bull Hitch D-Ring ($24)
Napier Precision Flat Fender Flares ($372)
Dirtbound Offroad Mojave Cut-N-Fold Rear Bumper
Dirtbound Offroad Mojave Tire Carrier
[CHECK] High Beam Offroad 'Predator' LED Headlights ($210)
[CHECK] Rough Country 5"x7" Rock Guards for Headlights ($10)
Replace Front LED Light Bar on Rack w/ Primalux 9" LED Round's x4 ($520)
Aussie Locker - Front ($280)
Dual Battery Setup ($325)
Napier Precision Hood Ventilation ($70)
Dometic Refrigerator w/ Slide and Travel Bag ($700)

OVERLAND & RECOVERY GEAR: $1,877
[CHECK] CVT Mt. Shasta Extended Pioneer RTT ($850)
[CHECK] Custom Full-Length Rack w/ Front and Side LED's ($550)
[CHECK] (2) 5 Gallon Jerry Cans ($40)
[CHECK] (2) 3.5 Gallon WaterBricks w/ Spigot ($49)
[CHECK] Custom Cargo Box ($120)
[CHECK] (2) Pelican iM2700 Storm Cases ($0)
[CHECK] Viair 88p Portable Compressor ($50)
[CHECK] ARB Inflator ($27)
[CHECK] Trasharoo ($45)
[CHECK] Hi-Lift 48" ($80)
[CHECK] Hi-Lift Bumper Lift ($32)
[CHECK] Boulder Tool Tire Repair Kit ($34)
[CHECK] Smittybilt XRC 9500 Winch ($200)
[CHECK] Ranger 25,000 lb Winch Hook ($40)
[CHECK] X-Bull Recovery Boards ($110)


Estimated Total Project Cost: WIP
Total Spent: $7,921 (thru 10-24-17)
 
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Se7en62

Adventure Seeker
Picked up an almost brand new set of 285/75R16 (33x11.5R16) Firestone Destination M/T's on TJ Rubicon wheels today. Then went by O'Reilly's and bought all of the fluids and filters I'll need for a couple services.

Now re-gearing has been added to the list, since's I have the abominable 3.07's coupled with 33's. Considering I plan to Overland and not necessarily rock-crawl, I'll probably be going with something between 4.11 and 4.56. Any suggestions?
 

SilicaRich

Wandering Inverted
Now re-gearing has been added to the list, since's I have the abominable 3.07's coupled with 33's. Considering I plan to Overland and not necessarily rock-crawl, I'll probably be going with something between 4.11 and 4.56. Any suggestions?

Guys with TJs that have AX-15 normally regear to 4.56 when running 33" tires if that has any correlation, same drivetrain. However, since you do plan to use the XJ as an overland vehicle the 4.11s would be a lot better when cruising on the highway on long trips.

Went ahead and Google'd for you:http://www.cherokeetalk.com/forum/f8/gears-ax15-33s-61834/
According to that, 4.56 gearing would be a good choice if you happen to fatten up your XJ with bumpers and other goodies.
 

Thirty-Nine

Explorer
I have 4.56 and 31x10.50s and it's a overgeared. Great throttle response and off-road performance. 33s would be perfect with 33s.
 

Se7en62

Adventure Seeker
Yanked the Grizzly wheels and BFG tires to sell off and jacked it up so work could begin.

de8cf03f4762c3ee496489a5ef2b666a.jpg


Drained everything...

acbf49f16d8885bc8c158ba82f7aeec1.jpg


I had a few minutes this evening, so I cleaned up the diffs before putting everything back together.

f7c01c08ef3a4100cf4aa4a7403fa8b7.jpg


Then tomorrow all the fluids will go back in, before I start on the undercarriage treatments and coatings.

e2f2c19c7f523a1afd49c33282654f09.jpg




Sent from my SM-G930V using Tapatalk
 
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HercDriver

Adventurer
Check local junk yards for a trac loc for cheap for that 8.25. Got mine for 55 bucks and threw in new clutch packs for 100. Good luck on the build!
 

Se7en62

Adventure Seeker
I'll be heading to one of the local yards here pretty soon. When i do, I'll keep an eye out for that Trac-lok. Was it a fairly easily installation, or did you need to change the backlash?

Here's my shopping list right now, so let me know if I should look for anything else?

NIXED
NIXED
NIXED
WJ or Dakota Power Steering Pump x1
NIXED
[CHECK] XJ Rear Seat x1
NIXED
[CHECK] XJ RR and RL Door Vent Glass and Seals x2
NIXED
NIXED
NIXED
Durango Steering Box x1
 
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HercDriver

Adventurer
If you can grab the whole axle and leave it in there you won't have to re do the backlash if you put it in your current axle.

I'll be heading to one of the local yards here pretty soon. When i do, I'll keep an eye out for that Trac-lok. Was it a fairly easily installation, or did you need to change the backlash?

Here's my shopping list right now, so let me know if I should look for anything else?

ZJ V8 Tie Rods x2
ZJ Pitman Arm x1
WJ Knuckles/Drag Link/Crossover Steering x1
WJ Power Steering Pump x1
WJ Bucket Seats x2
XJ Rear Seat x1
XJ Power Steering Pump (Leakless) x1
XJ RR and RL Door Vent Glass x2
XJ RL Door (Green) - My door latch is so locked up, I'm thinking I may just have to cut it open. :(
XJ Driver's Side Door Sills - Planning to cut mine out completely and replace with a new skin due to rust that originated from some poor body work in decades past.
TJ Rear Fender Flares x4
Durango Steering Box x1
 

Se7en62

Adventure Seeker
I've always been curious why people run 5w-40 Rotella in their 4.0s. Seems really heavy to me

Once you're over 100,000 miles, the clearances of the 4.0L begin to slacken. The 5w40 T6 offers me three benefits: Primarily T6 produces the least amount of wear compared to any other engine oil on the market. The secondary benefit is that it quiets a noisy engine. Third, it will allow me to go 6-7k between oil changes. I also upgraded to the Rotorcraft FL1A filter, which is a 0.5L larger oil filter that is only $3 and is available pretty much anywhere since it's commonly used on farm equipment and Ford pickup trucks.

Lastly, in a 3 month time span from March to May, my area of Central Texas could see day time temperatures from 30ºF to 100ºF, with cold-start temps from 30ºF to 85ºF. Therefore, I prefer an oil that's light enough to circulate quickly on start-up in the cold, but also thick enough to run all day in high temps without allowing my pressure to drop off in heavy traffic.

The reality of the 4.0L is that they aren't picky, so long as they're changed often.
 
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Se7en62

Adventure Seeker
After draining the oil, I noticed a little build up of oil at the back of the pan and traced it up to the backside of the valve cover. I swung over to O'Reilly's and picked up a valve cover gasket, oil pan gasket, and rear main crank seal. Last night, I knocked out the valve cover gasket. Tonight, I'll pull the oil pan and start cleaning it. I have limited time during the week, but I'm hoping to have the rest done by the end of the week.

Here's the top of the head after I removed the old gasket and cleaned the surface.
17191417_402530650108550_2139038775214200856_n.jpg

Fel-Pro definitely makes a quality gasket!
17190965_402530670108548_4796804188195593453_n.jpg

All buttoned up and looking much cleaner. - Except for that damn sticker, which I'll remove tonight.
17098298_402527293442219_3749934507386805868_n.jpg
 
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