Nui 'Ula - our '95 Ex-J!

SoCalMonty

Explorer
Hey everyone!

We just picked up an XJ for what I feel was a pretty good price, to replace the last ExPo vehicle we sold a couple years ago ('95 Montero SR, "Monty"). This will be the update thread for the new-to-us Ex-J!

Our new XJ:
'95 4.0L, 5 spd, 220k...starts, runs, drives great...evidence of some minor leaks (oil pan or filter housing, possibly valve cover)...33" KM2's, 4.5" RC long arm setup, crossover steering, frame stiffening plates front to rear (the front most plates are not yet welded in), rear rock bumper w/ recovery points, sliders, Warn M6000 winch with control box hard-wired in under the hood (but the PO sold the bumper separately, so I can't mount the winch). D35 non-C-clip with a broken axle shaft and re-geared to 3.55; D30HP front with stock 3.07's (with a 3.55 set already in a carrier that I need to install). 52" light bar wires and mounts installed, but the light bar was stolen. Stout cargo rack on top. We paid $2000. I am trying to be "all in" and trail ready for $3500 total ($1500 for stuff).

The original plans (so I can look back at it later, and laugh at how I didn't stick to any of this...):

Maint/gaskets/fluids, $250 ish
A-A-L to correct rear sag, $75 ish
Rear axle repair/replace, $300-400
New 33" A/T's, $625
Light bar, $100
Front winch bumper, $200 (sourced locally...still talking with seller...if this falls thru, I may sell the winch and that adds $400 or so to the budget).

Driving style/use:
We are moderate off-roaders, with trips once every 2-3 months. I have owned D35's on 33" XJ's, and I have never broken one; I'm more the "finesse" type (aka, I am NOT afraid of D35's, for the most part!). Trips in the SoCal area were anything in Big Bear and Panamint Valley mostly. The XJ will be street driven, and will need to tow a pop-up trailer. The next trip we have lined up (November, Panamint valley) will involve 2,000 miles of highway driving while towing the pop-up, so I am a fan of well-mannered A/T's for tires.

ACTUAL RUNNING TOTAL/MOD LIST:
*Check box at front indicates INSTALLED
*Vendor listed indicates PURCHASED


[x] 29sp C8.25 axle, $25 (local seller)
[x] 50" curved light bar, $78 (Amazon)
[x] Cargo box, $0
[x] 33x12.5 Cooper AT/3, $550 (Discount Tire Direct)
[x] D30 Aussie locker, $200 (Lokka.com)
[x] RC quick discos, $78 (Amazon)
[x] Monroe steering stabilzer, $23 (Amazon)
[x] OE pittman arm, $29 (Amazon)
[x] RE 4.5" leaf packs, $349 (Amazon)
[x] RE boomerang shackles, $110 (Amazon)
[x] Moog sway bar bushings, $10 (Amazon)
[x] Extended U bolts, $40 (Amazon)
[x] D30HP front axle w/knuckles, $119 (Junkyard)

[x] Smittybilt XRC front bumper
[x] Smittybilt XRC rear bumper and tire carrier ($900 combined, front and rear)
[x] Warn M6000 winch installed ($0, came with vehicle purchase)

[x] 4.56 gears installed ($1500)



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SoCalMonty

Explorer
The axle dilemma...

Boy, this ended up being a good time. LOL! So, we bought the XJ with what was said to be a broken rear axle shaft, but as it was a non C clip D35, I was able to drive it home. I knew at the onset that I'd be replacing the rear axle. What I *didn't* know until the next day, however, is that the D30 in the front had the swaybar brackets, stabilizer bracket, and right side upper control arm bracket all chopped off, so that the previous owner could run a 3-link, crossover steering setup...and the knuckles and pittman arm were drilled out for the heim joints, meaning I can't use them to put the stock drag link setup back in...

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After finding that out, and doing a bunch of research + cost estimates, I decided it would be best to go back to OE steering and a different D30 axle that has all the correct brackets (I want 4-link, and a swaybar, and I don't weld - I also needed to re-gear to match the rear). So I found an XJ in the JY that had a 27 spline C8.35 & D30HP in 3.55, which I purchased and brought home for about $255 out the door (with tax and core charges, on a half-price weekend). Literally that night, I found a 29 spline C8.25 in 3.55 with the seller asking $100 OBO, and I decided that I'd rather have that - so my wife went to pick it up while myself and a friend started prepping the XJ to swap it in. My wife ended up getting the 29 spline for only $25, and it came with brand new brake pads for the drums. :)

We swapped in the 29 spline, and I was left with 2 axles I wasn't going to use - the busted D35 we removed from my XJ, and the 27 spline 8.25 I brought home from the junkyard the day before. Since I had a junkyard receipt showing 2 axles, I attempted to return them to the yard for store credit - and it worked. So, I got $225 in store credit at the junkyard, plus I got rid of those axles that I was just going to be tripping over for the next year until I found a way to get rid of them.

All I'm left with now is the replacement D30HP with knuckles that I will be installing in the next 1-2 weeks, with an Aussie/Lokka up front, and a ZJ drag link setup with a new stabilizer, and a sway bar w/ discos. I will then put the D30 w/ crossover setup up for sale, maybe I can get $150 for it. Whew...axle dilemma solved! :)
 
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SoCalMonty

Explorer
Yesterday, she got the roof box and light bar installed. Today, she got new fluids in the engine, trans, and xfer case. :)

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