Canadian Expedition XJ

[Canadian Moose]

Hello Everybody! Welcome to my build thread.

Here is a current photo of my Jeep

Table of Contents

Day 1
Day 2 Engine Removal
Day 3 Gathering Parts
Day 4 TJ SOLD, Wheel upgrade
Day 5 Wheel painting
Day 6 Final engine install
Day 7 Rocker-Guard Painting
Day 8 Rad and Misc
Day 9 MIA
Day 10 It Runs!
Day 11 NSS FIX
Day 12 Engine Swap Recap and Financial's
Day 13 The other XJ's
Day 14 Treks Bumper Install
Day 15 RC 4.5" Lift Install
Day 16 Wheel Alignment + Fender
Day 17 ZJ/XJ Hitch and Skid
Day 18 Diff Oil Change and H4 Headlight install
Day 18 Continued HIDs Install
Day 19 Interior Project Stage 1
Day 20 Flares and CB Mount
Day 21 Aux Fan override, new leafs.
Day 22 Installed the bushwackers + Roof rack
Day 23 Snorkel and 4th flare
Day 24 Champion winch install
Day 25 Exhaust, small repairs, poser shots.

 

[Canadian Moose]

I really enjoy reading build threads. I figure I would start my own build thread which gives me a reason to document everything I do.

I am hoping that when finished this will be a larger and more practical Jeep than my TJ. It will have to be capable of taking on some tough trails yet be able to drive down the highway without problem. The deadline for this project will be June/July 2010. At the end of July I will be going on a 40-50day off-roading expedition, wheeling in places like Northern Ontario, New Mexico, Colorado, Utah, Arizona, California, up the west coast, BC and then ending back up in Alberta. It should add up to about 10,000miles or about 15,000km

I am planning on doing as much work myself as possible, however, I will pay a professional to have certain parts of the project completed (gearing). When I purchased my Jeep Tj just over a year ago I had a very limited knowledge of mechanics. Since then I have picked up endless knowledge and experience. I have done everything myself.


Here is a couple photos of my current Jeep. I have cleaned it up and fixed all the issues it had when I picked it up.

The Tj will be put up for sale in about a month.

 

[Canadian Moose]

Day 1

Day 1
Here is what I started with a few days ago (Nov 7, 2009) when I bought the XJ.

1998 XJ with 22x,xxx km *(136,000miles)
D30HP front
Chry 8.25 29 spline rear
4L Inline 6 with Auto
Air
Cruise
Brand new stock Snow tires on aluminum rims.
New brakes (and a E-brake that works!)

I already miss the expedition white!! The Chili Pepper Red is growing on me...

The suspension is a bit worn and rusty, and the exhaust will need some work. The jeep is in great condition rust wise. It was undercoated at some point. I bought it from the second owner (who owned it since 1999). Thanks to Waytec for pointing out the 8.25. I initially thought it was the D35.

The Bad:
Sized engine due to overheating/ gunk/gel in the rad. I bought it with the head/top of the engine partly removed.

Phil and Dave came over for some wrenching. We pushed the jeep into the shop with my TJ. We managed to get both engine mounts off and all but 2 tranny bolts. They are sure a big pain!

Thanks for the help guys!!!

 

[Canadian Moose]

Day 2

Day 2

Well my brother and I took at look at the jeep. We found and removed the remaining two tranny bolts (at the top of the engine). We then proceeded to hoist the engine out without to much trouble.

The top two bolt holes are the two bolts that gave us trouble. I removed them by reaching in to the engine bay. I don't think reaching in would have worked if the head and valve cover were still on.

And finally a quick photo of the donor engine. It is also from a xj. I was told it had 140,000km. It came from a rollover/ wrecked jeep.

Thanks for the help bro!


Most of the work will be completed on weekends. There are some loose ends I will need to take care of on the new engine. I hope to have it on the road with in three weeks.

Some of you may be wondering why I am giving up a clean and decently equipped Tj for an even older XJ... uni-body and all. Well right now I am on budget to have the Xj on the road with my 33s for really cheap! This allows for lots of room for upgrades and some cash to prepare the Xj for off highway expeditions.

Future mods include:
Rough Country's New Radius Long Arm 6.5 or 4.5(comes with t case skid)
gas tank and engine skids.
Custom tube bumpers and roof rack. (I am currently looking at buying a tube bender, or alternatively just making the measurements and getting someone to bend them.)
4.56 gearing
lockers
winch (s)

 

[Canadian Moose]

Day 3

Day 3 Gathering Parts


Well the donor motor is getting closer to being installed. I bought a serpentine belt, valve cover gasket and a intake manifold/exhaust manifold gasket.

I cleaned the intake manifold and reinstalled it. I installed the valve cover from the old engine. I installed the new alternator from the old engine. I will be installing the old engine's "new" water pump and throttle body as soon I get new gaskets.

I removed any useful parts off the old block and then dumped it.

Phil and I made a trip out to Kar Bashers. Picked up a complete air intake, gas tank skid and trailer hitch for $52.00.

 

[Canadian Moose]

Day 4

Day 4 TJ sold, Wheel upgrade

Some updates for you guys. I ended up selling my TJ last week. I sold it with the 28" rims and snow tires.

I had to gently persuade (with a grinder) my 33's on so at least I could roll it around while working on it. Yes, 33x12.5R15 on a XJ with no lift. Looks kinda silly... hopefully not for long.
Here are some photos.

I also picked up some 2005 Jeep Ravine wheels from a club member. They are alum and pretty beat up.

I got the engine into the jeep and started to bolt it up. Something is not quite right. The engine and tranny has a gap of about a inch.

 

[Canadian Moose]

Day 5

Day 5 Wheel painting

I removed the engine. Turns out I did not have the torque converter all the way in (2 clunks/ 2 splines).


Worked on the rims.
Before:

After

I ordered some black locking lug nuts from summit racing. I got a set of 30x9.5R15 Goodyear GSA's off a Edmonton Jeep member. I got the tires mounted at a local shop. I forgot to request white walls in. I can't complain because I got one heck of a deal!

I used Duplicolor Wheel Paint. The graphite color. I sanded them and sprayed them with zinc primer first. They will make good rims and tires till I can lift and regear it sometime this summer.

Looks a lot better.

 

[Canadian Moose]

Day 6

Day 6

Spent two hours today with a friend putting the engine back in after taking it out the other day. Started off by fooling around with the torque converter. Got it on this time. Best way I can describe it is that is has to go on in three stages/ clunks. Looking back this took a lot of my time and was the root of much frustration. You live and learn I guess.

It feels awesome to finally have a engine bolted in.

On a side note, I was driving the friend home around midnight. It was cold with some light snow. We came across an abandoned Grand Cherokee in the middle of a two lane road (in the country). The dangerous part about this was that it never had any lights on!!!!
It was kinda erie... like the coming of zombieland.... The doors were unlocked but the keys were no where to be found. I threw the tcase into neutral and pushed it off the road.
While on the phone with the police a Grand Wagoneer showed up. Turns out the guy was driving home and his alternator quit. He was running his jeep with the hood open and using one of those portable battery boosters to keep it going.
The guy was super grateful that we showed up and pushed his jeep off the road.
Always glad to help a fellow jeeper (even if they are dumb sometimes). :teehee:

 

[Canadian Moose]

Day 7

Day 7 Rocker-guard install

I only had a hour or two to work on the Jeep this evening. Decided I didnt want to get into the engine work so I addressed some of the cosmetic needs.

Here are some photos of the passenger side rockers. I left some space around the flares as tube flares and rock sliders are going on next week!!!!!

I taped off the area. I then sanded/ roughed up the surface. I applied this product to the rockers.

I purchased it from "Canadian Tire", which is a sporting goods and auto parts store. In many ways similar to Walmart, just better
I used the same product on the front of my TJ in post #1. It has lasted over a year with very minimal wear. I used roughly 1 can for each side of the XJ. The cans are about twice the size of a normal spray can and sell for $10 each.

I then painted over with a black spray paint to seal it off even better.

 

[Canadian Moose]

Day 8

Day 8

Started off by spending 2 hours in -20 grabbing some stuff from Kar Bashers. Got some random brackets/ bolts as well as an overhead console for $10.50 total! Totally worth it. The overhead console is the one with a compass and temp gauge. I also plan on installing LED's in the interior. Its going to be a fun install.

Spent a bit working on the engine bay. Got the battery figured out.

EDIT: Turns out I never needed the overhead console... please read on :elkgrin:

 

[Canadian Moose]

Day 9

Day 9 Rad and Misc

Making more headway. Got the new rad installed. The hardest part of all this is finding how stuff goes together. I wasn't the one that took the jeep apart, so it is quite the challenge finding bolts and plugs....

I need some AC lines, and a heater core hose. As well as two plugs don't match up (old and newer style). I am also missing part of the power steering bracket. Its almost ready to start though!

Immediate plans include:
Get it RUNNING!
ZJ Black Leather seats - Edit, not going this route
Windshield
Light tint on drivers and passenger windows
Tube Flares - Edit, not going this route
Rock Sliders - Homebrew?

My goal is to get this all done by New Years!

 

[Canadian Moose]

Day 10

Day 10 It runs!!!!!!

Fired up first try with no effort (besides the complications listed below), it actually surprised me! Not bad for sitting for 10 months. :2thumbsup:


I have spent the last two weeks starting university again, but also trying to track down a few rail with only one input.... to no avail.

A couple days ago I was getting really frustrated with the lack of progress. I headed down to Greggs Distributors (awesome company!) and picked up a whole pile of hoses, clamps and fittings. I made my own splitter for the fuel line and ran it to the rail. Its just temporary... and Redneck but it worked!. Also finished my one missing heater core hose as well as tranny lines. I am working on adding a small tranny cooler.

Well I turned the key... the fuel pump powered up...etc. Nothing else happened! The details are here http://www.jeepforum.com/forum/f11/...-power-but-wont-turn-over-947105/#post8693658

I ended up getting it running by "hotwiring" it. I am suspecting and hoping its the common NSS problem.


Stuff to get done:
Fix fuel leak (easy)
Finish tranny cooler -Edit, cooler will be added with electric fan at a later date
clean NSS
swap ignition coil (if the above doesnt fix the problem)

 

[Canadian Moose]

Day 11

Day 11

Spent a bit of time working on the Jeep. Cleaned the NSS which fixed my starting issues. Finished the tranny lines and changed the tranny oil.
I added some atf to the engine oil and let it run for 15 minutes. Then changed the engine oil.
Took some photos of the Jeep today.

Before

After

The maiden voyage

Stuck for the first time lol

Stuff to be fixed:
Dash lights
Alternator isnt working

Stuff ordered:
Frame stiffeners
Winch front bumper
Rear Shackles

 

[Canadian Moose]

Day 12

Day 12 – Engine Swap Recap

I have been driving the XJ for two weeks. It runs great. The battery is a little weak as it is my old TJ’s battery. I am leaning towards purchasing a Motormaster Gel Battery (aka Optima Red Top).

Major Hurdles:
- Mounting the torque converter. I really can’t stress how frustrating this was. Please look back a few posts if you are attempting it. Or send me a PM.
- Matching up 1994-6 electrical plugs with a 1998’s computer. I can’t begin to list all the plug and parts that I was missing or didn’t match up. Those trying this should know that it is possible. It just takes extra time.

If I could do it all over again….. I wouldn’t do it! Haha. The biggest problem was the fact that I never took the engine apart to begin with. The reality is that the engine is in and running. This is something I am proud of.

SPECIAL THANKS
Thanks to Phil (Flyingphil), Dave B, my Dad and Brother, as well as Bear (Bear Trax 4x4) and my neighbor, Lyell the mechanic. I couldn't have done it without you guys!

Mileage:
I ran the first tank by adding 60L (15gallons) of premium to the year old gas in the tank. I also added half a bottle of injector cleaner. I got 470km (292miles) and added 75L (19.8gallons). This puts me at 14.7MPG for winter driving. This is reasonable, I will probably hold off until spring then look at doing spark plugs, wires, distributor, mustang injectors and a change to the throttle body.

Financials (Stage 1 Complete)

Stage 2 Officially Starts NOW!

Interior
My interior reeks with cigarette smoke, my seats are worn out, I miss power locks and windows and I have not installed my Cb radio. Stay tuned for updates.

 

[Canadian Moose]

Day 13

Day 13 The other XJ's

Well it turns out Xj's around here are a dime a dozen. Or at least the ones I seem to stumble across.

I recently attended an insurance auction with my mind set on a 2000 XJ limited. I liked the idea of spare parts. Not to mention I really wanted to add power locks, windows and heated leather seats.

It’s pretty destroyed. The hood went through the windshield, and there is a large hole in the passenger side floor!


I also picked up a 1998 Cherokee Sport... Pretty much the same as mine! It has 230,000km (142,000miles, or 5k more than mine). A few other differences, it has power locks/ windows, np242 Transfer Case, front skid, gas tank skid, front tow hooks and a hitch. And another brand new set of snow tires!

I was toying with the idea of using the twin as my jeep.... but I think I will just stick to my original plan and build mine up. Way too much effort was put into bringing it to where it is now. What do you guys think?

I spent today getting the twin sale worthy.