94 JEEP XJ .. Daily Driver Lift Time !

[ChiefRocka]

Hey guys ....

My '94 Cherokee has been my DD for a while now, and it has been crying for attention lately.

We picked it up from our good friends (OG Owners) a while back who were going to donate it for $500 !! They helped us out, as my Corolla was totaled by a t-boner.

At the time it had 136K, and currently has 194K, and runs like a champ.

The bushings, shocks, tires, etc. were all shot, so the time had come.

Being as I was the honest husband I mentioned to the wife, that the best way to solve all the suspension problems was to install a "mild" lift kit () ... "It'll come with bushings and shocks too !"
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So, after saving some scrap metal money for a looong time, a few orders were placed .....

[ChiefRocka]

The plans are to stick with a mild tire size (31-32) as I don't want to regear as of yet ... but still get a good ride and good off road.

So after much research, I opted for a LONG ARM kit which will offer the best ride .... (oops, I thought I was speaking to the wife again...)
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I cant find stock pics of it, but here are some from Hollister Hills (2"booster lift)

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Those running boards quickly disappeared !!!

[ChiefRocka]

One of my most memorable times .... Hard crust, looked solid too me ....

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[ChiefRocka]

OK .... The FUN STUFF begins !!
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If this were a customer rig, it would of been in a day or so...but because its my own, it takes a back burner like all my projects ... :p
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One night last week .... (in this pic, the T/C was already pulled ... notice harness, and tranny fluid leaking)
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[ChiefRocka]

I decided to go with the RC 4.5-6.5" LONG ARM Kit. I found the listing on Ebay, but bypassed it and spoke directly with Adam's Driveshafts and he gave we a great deal ... which included a NEW CV style DL, and the necessary T/C SYE mod parts.

In case some of you are unaware, the stock XJ rear DL in a solid unit, with the slip in the T/C (like a 2wd tranny). Once a large lift is installed, the driveline could slip out. So the T/C MUST be converted using a SlipYokeEliminator kit, and new DL installed .....

Another thing, I wanted a lift that replaced the real leafs ... not a add-a-leaf style. My leafs were wasted (common with XJ's, when you treat them like a 1-ton truck and tow with them ... )

MISC pics .... new parts
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[ChiefRocka]

Last week sometime, I started with the rear.

The new rear leafs got a touch up of black paint ... might as well start fresh now .....
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Leafs in ... extended shackles from booster lift still in. I might order a new stock set if ends up too high ....
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NOTICE MY CUSTOM SINGLE IN DUAL OUT ( I MEAN SINGLE OUT ) FLOWMASTER .....
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Stock shackle was cut in half, and a 2x4 piece of rect. tubing welded in to net 2" originally ....
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[ChiefRocka]

Before I could start on the front, the T/C had to be back in the Jeep, with new crossmember....
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T/C SYE conversion .... Upon disassembly, I found the chain to be worn, and slacked pretty good ....
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[ChiefRocka]

Worn out ....
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Everything else looked good ...
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[ChiefRocka]

I figured it would be cheap insurance to install a new seal and o-ring in oil pump ....


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[ChiefRocka]

Now with the T/C in, I can get the jack out from under the tranny and support with the crossmember. Installed the T/C skid, Driveline, and finshed up the rear with the brake line ....
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[ChiefRocka]

Moving on to the front now .... FORKLIFTS are so handy !!
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Scrap steel ...
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Since the lift replaces all but two bushings, new stock replacements were installed. I welded in a piece of tubing to aid in pressing in the new bushing...
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I'll just leave it on the table for now ....
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[ChiefRocka]

Last night, we got the steering and front frame horn area reinforced.

Another common occurrence with the XJ (and Chevy trucks) is for the steering box area to crack. I found this a while ago, when I finally decided to investigate the creaking noises I had for several months. I had welded those last month. I decided to go with the JCR kit and do BOTH sides. This kit is a bolt on stiffener, which locates to all stock mounting points (box, swaybar, and bumper. This kit also prep the front frame area for a future winch bumper if wanted.

I will fab up my own steering box crossover brace later.

The kit came in raw steel, but since we have a powder coater across the parking lot, it makes it really convenient !! Especially, when we blast the parts in house , and 'throw' them in with other parts ....
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DORK...
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[ChiefRocka]

My little helper lending dad a hand in the blasting area .... :laugh::laugh:
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That's it for this early morning posting.

Maybe tonight, I will continue on the Jeep ....

[ChiefRocka]

I am back with a few more pics from a earlier this week ...

HOPE YOU ALL HAD A GREAT THANKSGIVING !!

My buddy who lives 2 hrs away was in town for two days on some work, and said here is some free labor. So he helped me out getting ahead, while I keep busy on customers rides ....

I had assembled the rod ends already, so it was a matter of assembling it all together. Long arms and axle go in ....
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Next came coils and shocks, and brake lines ....
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[ChiefRocka]

I had been hesitant on my rim style and tire make for weeks.

Always checking CL and nothing. I was getting ready to pull the trigger on a steel 15x8 tire and wheel package, when I decide to check CL one more time, good thing I did !!
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In my town, about 10 minutes away, a guy was selling 4 15x8 black powdercoated aluminum wheels for $300 ... I had to check them out ...
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When I arrived, I realized he had FIVE of them, and ended up getting them all for $250 !!
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Yes these are the POSER beadlocks, but I think I kinda like them. And unlike the steel poser locks, these have larger holes right on the wheels lip that should allow for better draining of mud/sand etc.

I like the blue, but my Jeep has the red stripe in the side trim, so they will be powered RED ....

[ChiefRocka]

Next up was tire size.

I remembered in my storage trailer, I had an old 33" yokohama ....
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So I mounted it to one of the wheels, and decided this will be the way to go.

Test fitted with axle on stands ....
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[ChiefRocka]

Next up was the front fenders and bumper.

I felt since I was headed this far, might as well lighten this thing up, remove some plastic, and gain some attitude ....
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Out came some tape lines and the 4" grinder ....
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I think the stock flares look cool, and will work for now ...
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[ChiefRocka]

Well now that the fenders are hacked ... what about the bumper ??
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Well my buddy showed up the next day, and continued on ... this time I let him hack away at the bumper. He gets a kick out of working with metal, so I told him take ur time, and go for it (with my supervision, of course)
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We decided on an angle, and went for it. This mod is temporary until a better bumper is fabbed up (so...probably never )
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[ChiefRocka]

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All done ... Now off to powder for a "wrinkle black" finish ...

[ChiefRocka]

Slowly hacking away at it when time allows ...

Here are a few more pics:

Delivery of the DuraTracs day after Thanksgiving, glad I went into work !
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Lots of tire pics, I know. (I'm excited about my new rubber)
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Decisions, Decisions ??
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[ChiefRocka]

This is about it so far ..... I decided to go black out on tires .... New sway bar bushings will be here this morning, then the bar can go back up with the disconnects. The rear axle cover is blasted and awaiting paint and reinstall. I seemed to have toasted my starter during my feverish pressure wash (original unit) so that will need to be addressed or replaced.
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Currently sitting at 4.5 in the front and the rear is slightly higher because of extended shackles. Debating if the 2" spacers should go back into the front ??
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[ChiefRocka]

A LITTLE MORE FREE TIME !!!
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I blasted and painted the stock Sway bar, and shown here awaiting the frame bushings ....
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Blasted the wheel lock socket, and painted (just got a new blast cabinet, can you tell ? )
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I decided to split the difference, and cut a 1" spacer for the front ... I'm still undecided, as it looks ok from the front, but when you approach from the rear of the Jeep, there is definitely a pronounced rake ...
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Bushings arrived, and the links were finished off ....
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Pitman arm was next ..... (GRRRR !!!!)
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[ChiefRocka]

Pulled outside for some sun .... cold sun, anyway ....
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One thing that always bothered me was one of my front turn signals was darker than the other side. Turns out, the inside plastic reflector never got enough 'plastic chrome' ... so using a heat gun, a razor blade, and some patience ... I cracked them open and used some chrome paint (never thought I would ever use that ! )
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After paint cured ... gorilla glue and some clamps, over night ....
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[ChiefRocka]

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I had the neighbor powder coat the bumpers, spoiler, and roof cross bars. Bumpers in a black wrinkle finish, and the spoiler/bars in a satin black.

Really happy how the bumpers turned out.

I spent this time just painting all the 'black' just because it was all faded and nasty. The white body is ok, dinged and scratched ... but the black was bad.
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Cleaned up the mopar hitch ...
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Diff cover was also done ....
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[ChiefRocka]

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Previous '00 GC booster install ...
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Had to re-visit a leaky valve cover. This time I replaced the grommets, elbows and the oil cap. Still need some correct hoses ...
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Fabbed up a new battery hold down out of some scrap steel .... Nothing goes to waste in the shop, even used the slugs left from hole-sawing ... Cold rolled was cut from the radiator core support cross bars from a '50 Chevy truck ...
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