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Thread: Rustoring an XJ

  1. #1
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    Rustoring an XJ

    Picked up a 2001 with 139,00km in March. Hoped to drive it to Lingham Lake this summer. Had other stuff going on and could not spend as much time on this jeep as I hoped. So far:
    March - took 242 apart to find out why it did not shift. Nothing wrong except the actual lever is hard to turn through the case... will have to tackle this again soon.
    April - seals and more seals : f/r pinons, t-case, aw4
    May - removed skids, welded a riv nut back in place
    June - front brakes
    July - rear brakes
    August - shocks (had to drill out rear upper bolts)
    September - clean up rust and tremclad rear and front axle/suspension
    October - Rear Main Seal, oil pan, starter
    November - put the wheels back on and took her for a drive, where did my year go? I did not get to the rocker panels nor did I make it to Lingham, oh well there is always next year. I took on this project as a "cheep jeep" concept that seems to be all the rage with Extreme 4x4, JP and FourWheeler, but man to bring a rusty worn out jeep back to life takes time!!!!
    Here are some pics, looking forward to spring... got pretty cold in the garage tonight.




    This jeep spenty some time off road and was driven in the salt. I wish the guy oil spayed it!!!!
    RUST SUCKS. Cheep Jeeps take time. I have about 2 grand total in this one:
    3.5 Rubicon Express lift, Tom Woods rear drive shaft, Upcountry skids and hooks, 31" Goodyear A/Ts.

    Jarek.
    2003 Rubicon - still stock 10 years later.
    1999 XJ - hard to beat an XJ for getting a canoe to the lake.
    1979 CJ7 (R.I.P.) - gone but not forgotten
    I am either fixing something or something is about to need fixing.

  2. #2
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    can't wait to see another grocery getter out on the trail!

  3. #3
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    nice
    rockin the 95 xj custom 4inch lift and 285/75/16 bfg mud terrain km2 and bds discos R.I.P

    98 xj 4.0L 5spd 4.5" zone lift and m/t sidebiters looking for 33s

  4. #4
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    Looks great so far!
    89 YJ, SOA, 35" MT's, a zillion parts to put on!
    05 F150, 35" Toyo's
    94 project Mustang - 95 Mustang Cobra - 96 6cyl Mustang (wife's)
    99 Cherokee, 4" Lift, 33" BFG's
    07 Durango, on 20" rims - Lifted soon!!!!!!!!!!!
    92 GSXR 1100

  5. #5
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    Rustoring , we always like more pics! Good stuff

  6. #6
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    I had this feeling that the jeep was mocking me....

    when the upper shock bolts gave, I knew I had some work to do.

    The jeep was actually laughing at me!!!!

    The picture below is the dirt I shook out of the skid plates. I had to make my own nut plate as again the rivnuts in the cross member gave.


    Working on this XJ makes me regret trading in my 99 XJ for the VW TDI Wagon. That XJ was oil sprayed and super maintained from new. I should have kept it... this thread would be a lot different. I had higher mileage but we drove to the east coast a few times (gas was .59 cents when I bought it). Chrysler should bring back a real Cherokee. The 4dr wrongler is close but it's no XJ. Only one beef - they all should have been made with full skids and hooks. TONS of used XJs these days but none have hooks - what gives?
    Jarek.

  7. #7
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    Jeeptoys - I'm in the same situation. I have a 99 that I snagged for cheap, but it needed a LOT of work. Now I only have the rockers to do, and then the rear springs.

    Then front hooks or hitch (I have both, neither is installed.)

    After that comes a slight lift, new tires, and more floor patching.

    And then...

    Aw heck, someone tell me why we do this to ourselves?

    And I agree with you. If Chrysler had kept the XJ like they originally said they were going to, it would've been awesome if they'd developed an off-road themed package that had the skidplates, hooks & hitch. As it was, I think you needed to chase down a couple of different packages before they'd include those goodies.

    Heck, a Rubicon-esque XJ wouldn't have needed much. 8.25 with a better limited slip, HP Dana 30 in the front, skidplates, hooks, 245/75/16 tires... some stickers, and Voila! Would've sold tons of them.

    If I was a Jeep, they'd have parted me out a LONG time ago.

    I'm a proud member of SOXJA ask me why!

    Krawlerz team member too!

    OF4WD Member # 5027

  8. #8
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    It's looking great! And I too am in the same boat. Only mine is an 88 that was undercoated and oil sprayed like every year. The mech at JJ said he has never seen soo much under coating on an XJ. In some places it's nearly 1/2" thick. And I mean EVERYTHING got the treatment. I had to use kerosene and a scraper to get to the diff plugs. They were glazed like a doghnut!

    Iv finished my floor, I'm half way threw doing the rockers now. So I feel your pain. When I cut one side out, there was a mouse and a nest inside it! I hate body work. So this may not turn out real smooth, but it will be functional... And a litle tougher then stock.

    Iv got no garage.. I do it all in my apartment parking lot! So don't feel so bad! Keep up the work, and remember your not the only one fighting the XJ fight!

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