Expedition XJ Mods for Under 10K

[Kyle Mackechnie]

Hey EP, thinking (very seriously) about doing some much needed mods to my XJ, and i dont want a 6" lift and 35s. i want a capable, long distance expedition XJ with enough provisions to last days in remote areas of Australia (where i live).

ive set a budget of 5-10k just for mods and am pretty sure i should be able to get a good expo vehicle for that.
i want atleast 31's and front and rear lockers (thinking front e-locker and rear aussie auto locker)

i was also looking at JKS Adjustable spring spacers and rough country shackle relocation kit with extended shacles to complement my 2" ARB OME HD Lift.

also all the usuals like winch, snorkel, already have a ARB steel bar so dont need that, and i was thinking of a rear tire carrier but not sure bout a roof rack, what do you guys think?

any other ideas for the 'perfect' expedition XJ would be much appreciated. thanks

 

[Jakeleverett]

A rack! That was/still is the single most useful addition I have made!
I use it probably once a week for a variety of things as well as when we go on extended vacations, camping, or offroading.
There is nothing more awesome than being able to use the roof as well as inside the car.
I try to utilize the rack for keeping my visibility.

 

[Kyle Mackechnie]

A rack! That was/still is the single most useful addition I have made!
I use it probably once a week for a variety of things as well as when we go on extended vacations, camping, or offroading.
There is nothing more awesome than being able to use the roof as well as inside the car.
I try to utilize the rack for keeping my visibility.

yeah thats what i was thinking...
what sort of inside storage do u have? drawers? or do u just put stuff in randomly?
and does the rack affect your MPG much, because ile 4.0L isnt the most economical engine in the world hahaha (still the best engine though)

 

[mudbutt]

what sort of inside storage do u have? drawers? or do u just put stuff in randomly?

Welcome to the forum... Take some time and look around. There is a sub forum near the bottom called "storage solutions". There's postings in there about drawer systems, roof racks, lock boxes, etc.

Here's one solution I came up with:
http://www.expeditionportal.com/for...unused-space?p=1010898&highlight=#post1010898

As far as spending $5-$10k on mods for an expedition rig, I would think that would build you a VERY nice XJ!

I would start with making it as reliable and as durable as possible. Make sure the cooling system is in the best possible shape it can be. XJ's have a reputation for running hot.

I replaced my radiator with a CFS heavy duty 3 row, replaced the stock water pump with a unit from Flowkooler, replaced the old E-fan with a new unit from VDO, new cap and thermostat.... I also added a B&M transmission cooler. The truck runs cool as ever.

Rock rails are a must... Transfer case skid at a minimum. I also have a gas tank skid.

Roof racks are handy, but they will affect your gas mileage in the long run. I bought a roof rack and have had it on their for about 3 years now. I recently took it off and don't plan on putting it back. I'm going to build something that is much lower profile and easy to put on & take off.

Again, make it reliable. Fix/replace anything that is questionable and can leave you broken down on the side of the road.

Carry spares. You won't need an entire replacement drivetrain. But you should have as a minimum, serpentine belt, fuses, bottle of coolant, etc... I would also carry a spare crank position sensor. I've never dealt with it, but I hear the XJ will go NOWHERE if it fails...

Again, welcome!

 

[Kyle Mackechnie]

And many people say the same..they miss when the jeep was smaller, more nibble & not much to worry about since everything is pretty much stock..track bar, control arms ect..your only beefing things up lol. Its much easier.

Most true thing ive heard since looking on forums... thanks

Ive budgeted adjustable coil spacers and adjustable shacle reloc. brackets with extended shackles, which means ill be able to raise it anywhere from 1.5" to 3.5" lift as i need.
And e-locker in front, aussie auto in rear which will give me double locked for a 1/4 of price of arbs so i can spend the extra money on repairing old parts.
I like the 3" 31's look on the xj so i really dont want any higher than that as it will also affect my cog which im very afraid of haha.
That video is proof you dont need 76" tires and 30" lift to run with the big trucks, and honestly, on the long distance trips i plan to run, there will probably not be many big trucks because of reliability, one guy in my club runs a 5" lift and 33's on his xj and is constantly replacing wheel bearings because of his spacers, i dont want that for me...

 

[brianwj]

I was happiest with my XJ with a 3inch lift, 31's, 4.10 gears, rack, rock rails and bumpers with rear tire carrier. The tires wore out so I went to a 5inch lift and 33's loved it offroad but hated long trips with it. My rack didn't cost me much in fuel as long as I didn't have a tire on it and the amount of times I used it I couldn't do without it now.

 

[Explorer 1]

I was happiest with my XJ with a 3inch lift, 31's, 4.10 gears, rack, rock rails and bumpers with rear tire carrier. The tires wore out so I went to a 5inch lift and 33's loved it offroad but hated long trips with it. My rack didn't cost me much in fuel as long as I didn't have a tire on it and the amount of times I used it I couldn't do without it now.

I agree, of all the changes I have made to my XJ, and there is enough to make a small pamplet, I would say the first lift I did with the 3" and the 31" BFG's was the biggest over all single improvement in trail ability while still leaving me with a happy highway vehicle. I also added both F&R ARB lockers which gave me the ability to climb up and over obstacles with a little bit on scraping on the rock rails.

Found this old picture of years ago:

Thanks,
Fred
Explorer 1

 

[MCObray]

I agree, of all the changes I have made to my XJ, and there is enough to make a small pamplet, I would say the first lift I did with the 3" and the 31" BFG's was the biggest over all single improvement in trail ability while still leaving me with a happy highway vehicle. I also added both F&R ARB lockers which gave me the ability to climb up and over obstacles with a little bit on scraping on the rock rails.

Found this old picture of years ago:

Thanks,
Fred
Explorer 1

Nice solid capture! That is the direction I am headed. Once I am out of college, i'll bump up another inch on top of my OME suspension, 31x10.5 KM2s, ARB Lockers F&R, and regear to 4:10s.

 

[TheBigJ]

Welcome to ExPo!

+1 on the Crank Position Sensor. Can't stress it enough. I'd have a couple extras on me for overlanding if I were you. Used to have an XJ and trust me if it decides not to work you will not pass go and will not collect $200.

Good luck on your build. Still love XJ's even though I have a JK now, you'll have a great rig with your budget. Someone already mentioned it but cooling system is pretty big too.

 

[Kyle Mackechnie]

yeah i agree with everything so far, what do you guys think about an aussie locker in the rear and an eaton elocker in the front? its 1/4 of the price of 2 air lockers

 

[88Xj]

Deffinetly a auto locker rear...but I would do a ARB up front. I like spartan over aussie, yes I've had both. The aussie seems much louder with the popping/clicking/ratcheting. The Spartan does it but is no where near as loud. Both bought new, both rear lockers in a c8.25.

I would strongly you to get at least 1" HD leafs. The stock leafs won't carry any weight without sagging. So when loaded your gonna be dragging *** litterally lol. Honestly 3" leafs & stock shackles simplier & cheaper..but if its your preference I would strongly urg you do at least a 1" Hd pack to be able to carry the added weight of camping/trail gear!


Remember this 'KISS' keep it stupid simple. As close to stock as possible..stock stock track bar, no more than 3", just worry about beefing things up! And added load capacity. Expo'ing is a heavy venture.
Thats why I was suggesting the slightly stiffer coil. If your doing acco's (I'm looking into this as well) then you can grab a v8 Zj coil from any junkyard for 20 bucks or so. They have a spring rate of 189lbs vs the stock 155lbs..at stock height I could tell the difference between the 2. I liked the Zj coil much more, felt better in & out of turns. It just felt more planted vs the stock coils which felt soft honestly..to soft. With a winch or anything up front the stock Xj coils would be to soft I would think. Just some more food for thought. When lifting you always want a little more spring rate to compensate for the added body roll.
You seem like your off to a good start..did you already have a Xj or no?

 

[Kyle Mackechnie]

Yeah, i already have 2" ARB OME HD Lift with front and rear springs and nitro charger shocks, i just wanted abit more height out of it

 

[jeep-N-montero]

In the front I would use an Ox Locker over an ARB or e-locker. And down the road I would look into installing a long arm setup in the front, as over time the factory arm mounts will crack and bend, plus it will ride smoother.

 

[jscusmcvet]

Deffinetly a auto locker rear...but I would do a ARB up front. I like spartan over aussie, yes I've had both. The aussie seems much louder with the popping/clicking/ratcheting. The Spartan does it but is no where near as loud. Both bought new, both rear lockers in a c8.25.

Remember this 'KISS' keep it stupid simple. As close to stock as possible..stock stock track bar, no more than 3", just worry about beefing things up! And added load capacity. Expo'ing is a heavy venture.

I agree with these comments. I was amazed at the invisible nature of the spartan locker I had in my XJ. Remarkably easy install, phantom on the road, perfect off road, cheap. Can't beat that.

As far as the KISS concept, the XJ is just right with a 3" lift, locker, skids and maybe some trimming...

Good luck to you.

John

 

[88Xj]

I'm at the turning roads for mine honestly..leave it as is & drive it until I find a older mid 80's diesel susburban..buy said burb & build it. Should get similar mileage...probably 15/20, more space & a real frame! 33x10.5's & a very mild 2-3" lift. Best thing here, no smog & biofuel option & its literally the ultimate rig..can seat 8, 6bt swap & it'll tow anything, damn secure with its size & weight. And offroad they are like a big mountain goat, climb great, just alittle long/wide so you gotta keep mind of that.
Or keep my xj, currently getting 18/22..3" and 31's & get a little bit crazier with it..redo the crappy factory wiring, waggy front d44 & izusu rear d44 swap (very similar width to stock, just stronger all in all & the same bolt pattern). Finally start a aluminum roof rack, maybe even do front & rear bumpers. Also a Rubicon 241OR tcase or Atlas. I love my 5speed, and a 4:1 or deeper would be sooo nice, just don't wanna spend that kinda money unless I truely keep the rig!


I love the burbs size..I would ditch the 3rd row & use the extra space, also a cage would be nice in it since theres sooo much space. Its sooooo damn hard to decide! My jeep being 25 years old, I'm honestly worried about the unibody. I have mid-stiffeners from ruffstuff but would love a simple cage. I don't race or anything..main points would be help stiffen the body & be strong enough for a flop at most, and be as out of the way as physically possible..I just think the cage would kill space even more in the small XJ. Idk maybe you guys can help me here?
My xj with the extra weight a low pro. roof rack would probably end up around 16-17 city & 20-21 highway. The burb I wouldn't need a rack with all the extra space & with the diesel it would get similar mileage..and no smog which is always nice but not a deciding factor! Help me here.

Sorry to high jack Kyle.