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fraz
07-11-13, 01:08 PM
Hey everyone

I met a few of you last night at the club meeting (Lachlan in the Ultimate Suspension shirt), and some have probably seen my build up over on Ausjeep. I'll just cut and shut the build process to date on here and will update as more gets done.

A lot of the younger guys at work had started picking up old solid-axle vehicles for VERY cheap. Before I bought the XJ, there was an '88 GQ Patrol with 400K+ on the clock, an '84 60 series cruiser getting rebuilt and a leaf/leaf hilux just at work alone. Everyone kept pestering me to get something old-school that I could go to town on, but do so without breaking the bank.

After talking to a number of overseas and local distributors, I settled on the XJ Cherokee. The main reason was the 5-link front end, which offers heaps more flex in the front from standard than any of the above vehicles. I just had to find the right one at the right price.

Anyway, a very clean '96 Sport came up on Gumtree for $1400 with auto issues. I haggled the seller down to $900 without rego, and the deal was done. Picked the car up the next night and towed it home. Put 6 months rego on it the day after that and she was good to go. Drove it around for a couple of weeks, and found a couple of issues:
-Wouldn't start when hot, and would randomly stall when changing gears after driving around town;
-Had to change gears manually, meaning a loss of 2nd gear.
These were rectified, which I'll cover later.

The whole point of this build is to create the most capable off-roader for under $9k. So far I've spent around $3k including rego, insurance, servicing and initial purchase, so I'm off to a fairly good start. I'll be building as much as I can myself for this (rear bar, shocks, etc.) to keep the cost down. And, of course, a photo of it on the night I picked it up:

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1170827_10151580487866336_1512966620_n.jpg

Anyway, onto the build-

First issue: Inconsistent starting habits.

After testing the injectors, fuel pump and relay, dizzy and everything else I could think of, it was left down to the Crank Angle Sensor. Sure enough, it was malfunctioning. New one was ordered through work and fitted it up, all good. Starts up within the first couple of cranks now.

Next problem: Non-auto auto.

I had to manually shift through the gears as the auto box would simply try and take off from a stand-still in 4th if left in D. This was alright for a while, but the TC wouldn't lock-up on the highway either, which was seriously killing the fuel economy. I know the XJ's aren't great on fuel, but 15L/100km on the highway was a bit crap.

Anyway, after testing the inhibitor switch and checking all fuses and relays for the transmission ECU, the only thing left was to pull it apart. Did some forum surfing on AusJeepOffroad, and found a member with identical symptoms that were fixed by replacing the solenoids. Ordered new solenoids, along with a filter kit and new fluid.

2.5hrs on the hoist, and it was all done. Had a little issue with the clearance between the pan, exhaust and crossmember, but got there in the end. New gear all fitted up with fresh new oil, and it was running like a dream. Now need to replace the trans. cooler lines as they're leaking.

Next up - New tyres.

I swapped the original steelies and road tyres with a friend who has a TJ he's trying to sell. Also helped him out with a few bits on his 80 series, so got 31x10.5R15 retread muddies on TJ alloys for free. Just a shame they didn't fit in the guards properly haha.

https://lh5.googleusercontent.com/-9filkGiLV5Y/UilxDQg2ELI/AAAAAAAAAl4/fwh9nICD40Q/s640/31%2527s-2.jpg

Then the suspension turned up at work. 2" Coils, 3" leaves, Superpro bushes and U-bolts for now. Fitted them up and wondered why it looked funny.

https://lh5.googleusercontent.com/-iMNUNdtim3E/Ui0POUk6vlI/AAAAAAAAAms/TETt0ps555g/s640/side-on%2520lifted.jpg

I now leave my toolbox in the boot to keep the back down and make it ride a little nicer, at least till I build new shocks for it. :lol: Having the toolbox in the back is also just a bonus for when it requires impromptu maintenance.

Onwards and upwards!

Ordered a set of sliders off the AusJeep forum, then they sat in the garage for about a month before getting fitted up. Fitted them over 3 nights with lots of swearing, bloodied knuckles and broken drill bits.

Next - Steering Bits. Replaced the Tie Rod and panhard with HD units from Wooders Garage, and the Steering Damper with a HD Foam Cell unit. Then got a rough alignment (castor is still WAY out).

Finally - New Bump-stops and coil-spacers. 30mm spacers from SuperPro for the front, and Rubicon Express 1" bumpstops from Wooders Garage. Took a little creative thinking to get them fitted, but all in now and good to have two bump-stops again.

Here's how she sits today with close to 300kg in the back :

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/q77/s720x720/1392052_10151747972146336_876470333_n.jpg

And a gratuitous flex shot:
https://lh5.googleusercontent.com/-FYuSdhirhaI/Ui7TqIAiEdI/AAAAAAAAAm8/Zi1XZgI8_80/s800/all%2520flexxed%2520up.jpg

Managed to finish building the front shocks at work on Tuesday. Machined the cross-bar for the lower mount after work, and pressed the bushes and cross-bars into the shocks before I left. Got home and started to pull out the original monotubes. Got them out without too much fuss thankfully, as this was only the beginning.

Out with the old:
https://lh3.googleusercontent.com/-9ONHjauOM6A/UniuSlxMwVI/AAAAAAAAAoE/cz5qd2zVINE/s400/20131105_191322.jpg

Compare the pair:
https://lh6.googleusercontent.com/-za_7wAuG4EA/Unity6x2z2I/AAAAAAAAAnk/bTK35_04e9o/s640/20131105_191140.jpg

It wasn't until I fitted the new shocks to the vehicle that I realised my mistake - I'd forgotten to measure the size of the lower shock eye.

The eye is a little too big for the mounting bracket, so the shock won't sit down properly. I spent so long making sure I'd grabbed the right cross-bars and was getting the lengths and valving right, that I'd forgotten to make sure the lower eye would actually fit and just assumed it would.

Missed it by that much...
https://lh6.googleusercontent.com/-x9Olt1sANDM/UniuKEUJ-AI/AAAAAAAAAn8/Pu64aiYaFJ0/s640/20131105_193354.jpg

I'll grab the dremel from work tomorrow and grind out the mounts where necessary. On the bright side, the new bump-stops look like they'll limit the up-travel just enough for the shocks to work on full up-travel. Down travel isn't an issue, as these shocks have more than enough movement in them with the standard control arms (620mm/375mm open/closed).

Also managed to pick up an old alloy non-winch bar from work for very cheap. Currently painted white, but I'll be sanding it back and painting it in grey hammer-tone before fitting it to the XJ. Will also be modifying it a little to get the approach angles as good as, if not better than standard. Might even make a winch mounting plate out of 8mm steel C-section for further down the track.

Anyway, that's all for now. I hope to meet more of the members out on trips and such, and should hopefully be able to organise a trip or two myself once I get to know this place a little better.

Wolfe
07-11-13, 05:33 PM
Great thread!!!!! Welcome an xj is a fantastic vehicle. I've just sold mine so I can afford to continue work on my cj7.
The xj was awesome and never failed to get me where I wanted.
Excellent all round vehicle can be mild or wild tourer to rock monster. Very versatile.
Welcome hope you have a great time in the club.

Cpage66
07-11-13, 06:02 PM
Me likee the Xjee...

I've got one to putt around town in and to take off road a bit as well. No lift and not really planning to put one on. We've swapped a Chrysler 8.25" in the rear with a full Detroit and went ahead and replaced the front D30 for one I had with a Spartan locker. Both were already 4.10 geared. Latest mod has been bonnet louvers which added some bling...(Or so says Steve F! LOL). Fun little sleeper so far...

Steve F
07-11-13, 07:59 PM
For those lower shock mounts just make a spacer and raise the mount slightly if you have the compression available in the shocks. As an aside you cant really go wrong with an XJ :)

Cheers
Steve

redrubi
07-11-13, 08:50 PM
Welcome to the club Mate!!

It's not a JK! But it'll do!!! LOL:highly_amused:

Cheers

Andy & Charlene:pirate:

fraz
07-11-13, 10:27 PM
Thanks for the warm welcome everyone! :)


For those lower shock mounts just make a spacer and raise the mount slightly if you have the compression available in the shocks.

I thought about that, but it's just as easy to grind out the opening with a dremel. The closed length is already pushing it with the RE 1" bump-stops, so I'd rather keep it lower if I could. I haven't had a chance to take it off-road yet, but there's still some bits and pieces that need doing and checking before I take it out in the rough stuff.

Cheers,
Fraz

fraz
08-11-13, 08:39 PM
Ground out the lower shock mounts on the front and fitted the new shocks. Aren't Dremel's wonderful things? :highly_amused:


https://lh5.googleusercontent.com/-sionl8YFIuw/UnyvJiUCU5I/AAAAAAAAAoc/nKuwnYv8GQY/s640/20131108_192302.jpg


https://lh3.googleusercontent.com/-x2jNHsLwe4A/UnyvApcsrnI/AAAAAAAAAoU/fZ5CsIuyCMI/s640/20131108_192640.jpg

fraz
16-11-13, 10:19 AM
Bought a full set of second hand RE Super-Flex short arms off rob.rock on AJOR and fitted them up last night. Then proceeded to take it for it's first drive off-road with the guys from work.


Got off the main road, aired down to 15psi on the 31's (could have gone lower, 15 didn't bag them out too much) and disconnected the sway-bar. I've gotta say, I was pretty impressed with how it all went. A few of the guys commented on how stable it was, and it was definitely different to driving the Triton off-road. No more picking the perfect line to keep the front wheels on the ground. Just point, shoot and maybe a little left-foot brake to keep it in check.


https://lh3.googleusercontent.com/-AifPT0YDw_E/Uoad3Gb43jI/AAAAAAAAAos/2jfeClSoQgE/s800/1398169_10151781513036129_136935018_o.jpg


Next up - Drop boxes and longer shocks on the front (again). Then SYE and CV-style double-cardan tail shaft. 8)

fraz
02-01-14, 06:51 PM
Some new bits and pieces have been added, and I've also taken it for a full-days off-roading now too! Still getting used to driving it off-road, as the body tends to follow what the rear wheels are doing, where I'm used to the body following the IFS setup in the triton.


First off, I fitted up some RE Swaybar Disconnects. Need to relocate the "disconnected" fob, as it scrubs against the tyre at full compression. :(


Anyway, I had to re-do the cooling system as the original radiator was leaking like a sieve. I would have to top the overflow bottle up every day, asd it was leaking from a couple of different places. I've since installed an ADRAD HD Copper/Brass 2-row radiator, and it's fixed the leaking issues. The original rad in mine was already a copper/brass by the looks of it, as it only ever overheated when stationary. Because of this, I've also replaced the viscous fan coupling with a Dayco unit. The fact that I can actually hear the fan now is a big improvement over the original, and it doesn't go over 105 in traffic either! :D


While I had everything apart, I fitted a 7-row auto cooler in front of the A/C auxiliary fan. Now there's no issues with the auto overheating in stop-start traffic, causing it to slip and carry on especially in reverse. I've also wired up the aux. fan to a separate switch so that I can turn it on whenever I want to keep the engine and auto cool.


Original auto cooler above the new 7-row unit:
https://lh4.googleusercontent.com/-0yjb3yfmb4k/UsUVQ-6zzlI/AAAAAAAAApc/czgI2SyBb1Q/s640/20131207_160109.jpg


All fitted up, sits nice and snug behind the grille:
https://lh5.googleusercontent.com/-HvA8ikP_XWg/UsUVAC9nbzI/AAAAAAAAApU/XJ3WBaXGJTI/s640/20131207_160808.jpg
https://lh4.googleusercontent.com/-xXuQn18U5PI/UsUUykB4MQI/AAAAAAAAApM/sx44ouQE3Fw/s640/20131207_204744.jpg


Fancy wiring for A/C fan:
https://lh3.googleusercontent.com/-x1pXjFJucYE/UsUUmNUVRdI/AAAAAAAAApE/ls6keq9-AZQ/s640/20131207_204754.jpg


Next round for the cooling system is to replace the water pump, thermostat and housing with High-flow ones from Hesco. I'll also (hopefully) be fitting up a fiberglass cowl to the bonnet to help improve the engine bay temps. I'm currently halfway through installing the new audio system though, so that may take a while before I'm back on track. :lol:

Also, a few action shots from the Lithgow trip last month:


http://farm3.staticflickr.com/2808/11283342245_426f54489c.jpg


http://farm6.staticflickr.com/5543/11298879024_e47b4ea5db.jpg


http://farm8.staticflickr.com/7360/11286445913_3c515cf65a.jpg

fraz
29-01-14, 03:22 PM
Latest edition to the budget build is a set of Adjustable 2" Patrol rear shocks. Pulled them off a vehicle at work as the customer wanted gas-charged shocks instead of the foam-cell adjustables, and they'd only been on his vehicle 3-4 months. 8) They're a little longer than the OE's on closed length at 415mm, however it's nothing a 2" bump-stop spacer can't fix. ;) Open length is around 650mm, so have removed the brake-line from the mount for now and cable-tied the hard-line further back at the bend.


Down-Travel with old shocks-
https://lh6.googleusercontent.com/-H_fsM-kC2qU/Uud6J8PLBbI/AAAAAAAAAqY/fEMyPEA9OTE/s640/20140128_184735.jpg


Old vs. New
https://lh6.googleusercontent.com/-Rixgr5oLHK8/Uud6ClGYb4I/AAAAAAAAAqQ/TEE4ADMO0yg/s640/20140128_200235.jpg


Down-travel with new shocks-
https://lh4.googleusercontent.com/-ooGc9PpAYqQ/Uud6R5BRQ7I/AAAAAAAAAqg/gBgygn2H7b8/s640/20140128_185214.jpg


Brake line mod-
https://lh6.googleusercontent.com/-r0NeR7bUitw/Uud53oh0_gI/AAAAAAAAAqI/4SvuaBF7Z1g/s400/20140128_201257.jpg


Also in the process of installing the new stereo set-up. 4x 6.5" 90W RMS component speakers and an 8" 300W sub in the back. Powered by 2 amps; door speakers run through a 4x100W amp and the sub has it's own 300W monoblock. Topped off with a Pioneer bluetooth and USB single din head-unit, it should be nice and clear at all volumes.

rupicon
01-02-14, 08:50 PM
I love the low buck projects and the XJs are a great base

fraz
02-02-14, 05:36 PM
Managed to get some more work done to this over the last couple of days. Have rego coming up shortly so needed to get rid of all the oil leaks. Replaced the sump gasket and rear-main seal, although I have a horrible suspicion that the front main seal is either on its way out or already gone. Lots of crud behind the harmonic balancer, along with coolant dripping from somewhere. :(


Anyway, back to the rear end to finish what I previously started:


Made up a couple of bump-stop spacers for the rear end at work. Had some spare 50x75mm RHS at work that was 2.5mm thick. Originally started making them from 50x65mmx1.5, but decided they wouldn't be strong enough. These should allow me to run a 4" patrol rear shock without bottoming out the shock, which allows me time to upgrade as more parts turn up. This should also hopefully stop the 31's from scrubbing, although I may be getting 32's or 33's soon, just have to wait and see.


Also ordered RE extended shackles from Wooders, and bought the 6" coils and shackle relocation brackets off Tuffeb on AJOR. Looking forward to it all turning up so I can test it on the trails.


Anyway, photo time!


Bump-stop spacer - 75mm spacing-
https://lh4.googleusercontent.com/-WuC65onBPOs/Uu2H1567wvI/AAAAAAAAAqw/rvM-F5iehl4/s640/20140201_182743.jpg


Bump-stops bolted to the bracket using M14x1.5 flange nuts and high tensile bolts-
https://lh4.googleusercontent.com/-H3iqgUPi_ro/Uu2H9yMvDZI/AAAAAAAAAq4/-xu6RLcmRNE/s640/20140201_183719.jpg


Bolted together-
https://lh6.googleusercontent.com/-beIdmwO6LDQ/Uu2IejQW2fI/AAAAAAAAArQ/VZ2oqjQcTgs/s640/20140201_183712.jpg


Comparison of old clearance to new clearance-
https://lh4.googleusercontent.com/-zWifEj8jsAA/Uu2IoOO6bmI/AAAAAAAAArY/WRAnnqb3PQw/s640/20140201_182643.jpg


https://lh5.googleusercontent.com/-U3iDOSCwEpQ/Uu2IUIp3GQI/AAAAAAAAArI/IJCIOGa14d4/s640/20140201_182654.jpg


While I was at it, I also made up a Brake-line relocation bracket. This can be straightened out to further space the brake line down if need be, but should be fine for the time being.


https://lh4.googleusercontent.com/-Q6D82PIsEOc/Uu2IH_L7VmI/AAAAAAAAArA/x79O7PBrYMg/s640/20140202_104628.jpg

Wooders
05-02-14, 05:17 PM
Regarxing the bumpstop spacer, I'd recommend welding a rectangular bit in the middle to prevent it flattening out under impact.
Also if you want a neater solution for the handbrake line, id use 2x rhs line from the later model.
Sent from my GT-N7105T using Tapatalk

fraz
06-02-14, 12:13 PM
I did think about strengthening the bracket further, but decided against simply because it's sitting a lot lower at the moment than it will in the near future. Cheers for the heads up about the handbrake cables too, will keep that in mind. ;)

fraz
24-02-14, 12:01 PM
Finally got around to fitting up the snorkel. Pretty simple install as long as you line the template up correctly :% Came up looking pretty good though, and passed the air-tight test (hand over intake pipe) so I know it's waterproof. :D

https://lh6.googleusercontent.com/-muPsINo8oGQ/UwmcBdtr6UI/AAAAAAAAAsw/9wpzID3sx8E/s640/20140223_174210.jpg


Hasn't made any change to economy that I can see, although engine temps are slightly lower at cruise (60km/h+) and power seems to be a little better above 80.


As I had to remove the original washer bottle, what have people used as replacements? I'm not afraid to modify the original washer bottle if need be, however would like something with 3 washer pumps so I can set up a radiator spray.


Will also be pulling apart the cooling system (again) to replace the thermostat housing and thermostat, but not before some new fun-bits arrive at work. 8)

fraz
05-03-17, 11:07 AM
So it's been a while since I've been on here, or even active as a club member. For a while I had a 76 Series Landcruiser as my main car, but the black jeep has always been around. A few things forced me to let the registration lapse on the black jeep, however it's always been there waiting to get back on the road. Late last year a friend was selling their XJ Cherokee, and it was too good of a deal to pass up. Same age as mine (96 model), but was a limited with all the features. Leather trim, electric seats, cruise control, the works. Anyway, I bought it, put some rego on it and set about transferring all the parts from the old black Sport into the blue Limited.

First up was Drivetrain, which took around 6 months of on-again off-again work to swap. The Sport had a completely new cooling and belt system, and the motor was a lot stronger with less kms. While the motors were out, I got hold of a late-model TJ intake manifold and a new set of exhaust headers, so fitted them up. Motor in, drove the car around for a few weeks, then started to get stuck into it.

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/16999172_10155155802376336_9210164705475503350_n.j pg?oh=079851d4c9a26bfba5fb0653e88729f9&oe=592ACC06

Fitted the lift kit from the old Sport, albeit with a couple of changes. Kept the short-arm and drop-box combo because it rode perfectly at 3", but swapped the coils for some 4" coils instead. Also fitted a 1.5" bump-stop spacer to the diff as well as the 1" extended poly bump-stops so that it's all working properly when the new shocks turn up. Rear suspension was the same Lovell's Leafs, but with a set of extended shackles thrown in too. The car sits at a perfect 4" front and 4.5" rear, exactly how I wanted it set up. Also ditched the rear sway-bar while fitting the lift, as it wasn't needed with the heavier leaf springs. Also installed the Hyline Off-road hood louvre kit I bought probably 12 months ago, just to help a little when off-road and towing.

After all that, took the old girl out on Thursday night for some fun. Following a mate with his 4" patrol on 35's, the XJ didn't miss a beat. The only thing that held me up was the highway tyres compared to his muddies. So a set of 31's are in order I think. ;)

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/17021370_10155160637646336_1079351574603637509_n.j pg?oh=7769ef6c450c054700c1222ba4a316b2&oe=5937615C

Anyway, that's all for now. Will be updating a bit more as it goes, and hopefully see you guys out on the tracks again.

Elio S
12-03-17, 08:33 AM
That flex!!! You still at The Ultimate Suspension?? That's good advertising for the business lol

Steve F
12-03-17, 09:58 PM
So it's been a while since I've been on here, or even active as a club member. For a while I had a 76 Series Landcruiser as my main car, but the black jeep has always been around. A few things forced me to let the registration lapse on the black jeep, however it's always been there waiting to get back on the road. Late last year a friend was selling their XJ Cherokee, and it was too good of a deal to pass up. Same age as mine (96 model), but was a limited with all the features. Leather trim, electric seats, cruise control, the works. Anyway, I bought it, put some rego on it and set about transferring all the parts from the old black Sport into the blue Limited.

First up was Drivetrain, which took around 6 months of on-again off-again work to swap. The Sport had a completely new cooling and belt system, and the motor was a lot stronger with less kms. While the motors were out, I got hold of a late-model TJ intake manifold and a new set of exhaust headers, so fitted them up. Motor in, drove the car around for a few weeks, then started to get stuck into it.

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/16999172_10155155802376336_9210164705475503350_n.j pg?oh=079851d4c9a26bfba5fb0653e88729f9&oe=592ACC06

Fitted the lift kit from the old Sport, albeit with a couple of changes. Kept the short-arm and drop-box combo because it rode perfectly at 3", but swapped the coils for some 4" coils instead. Also fitted a 1.5" bump-stop spacer to the diff as well as the 1" extended poly bump-stops so that it's all working properly when the new shocks turn up. Rear suspension was the same Lovell's Leafs, but with a set of extended shackles thrown in too. The car sits at a perfect 4" front and 4.5" rear, exactly how I wanted it set up. Also ditched the rear sway-bar while fitting the lift, as it wasn't needed with the heavier leaf springs. Also installed the Hyline Off-road hood louvre kit I bought probably 12 months ago, just to help a little when off-road and towing.

After all that, took the old girl out on Thursday night for some fun. Following a mate with his 4" patrol on 35's, the XJ didn't miss a beat. The only thing that held me up was the highway tyres compared to his muddies. So a set of 31's are in order I think. ;)

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/17021370_10155160637646336_1079351574603637509_n.j pg?oh=7769ef6c450c054700c1222ba4a316b2&oe=5937615C

Anyway, that's all for now. Will be updating a bit more as it goes, and hopefully see you guys out on the tracks again.

I see shoving coils back in at the side of the track in your future ;)

Cheers
Steve

fraz
14-03-17, 10:51 PM
That flex!!! You still at The Ultimate Suspension?? That's good advertising for the business lol
Hey mate, no longer at Ultimate, but still using all the knowledge I gained there. Now working at Heasman Steering as it's a lot closer to home. ;)


I see shoving coils back in at the side of the track in your future ;)
Hopefully not haha, there's about 1.5" of bump-stop mount holding the coil in, plus the length of the bumpstops. Then there's the factory coil-retainers on the diff ;) I may or may not have ordered a set of 6" Raised Bilsteins at work, which work out to about 4" longer extended than current shocks in the front (720mm vs. 670mm), and longer for the rear (700mm vs. 645mm). Just need to get the leafs working a little better, so may pull a leaf out and give it a little more camber at work. Will have to wait and see

Steve F
15-03-17, 12:10 AM
Those retainers don't last long with lots of flex and spring movement. Both of bent up and were useless.

Cheers
Steve

Sent from my SM-G935F using Tapatalk

fraz
15-03-17, 10:06 AM
Those retainers don't last long with lots of flex and spring movement. Both of bent up and were useless.

Cheers
Steve

Sent from my SM-G935F using Tapatalk
Thats a good point. I did get some of the HD retainers from Iron Rock Offroad when i bought the hack-n-tap kit, so might have to throw those on sooner rather than later.

Cheers :)

Sent from my SM-G920I using Tapatalk

darksidecustoms
31-03-17, 09:59 AM
Subscribed :-)
Glad to see you're still around. Heasmans are a great crew, used to deal with them in Ferrari/Formula 3 space back in the day and they set up a VN wagon for me.


Sent from my iPhone using Tapatalk