Gjeep

Getting small things done…Took apart all the new rocker switches and swapped casing. Each rocker case has a guide specific to the opening it is supposed to reside in from the factory. Since I’m re-organizing the switch line up left to right, I needed to swap the casing. The only one that was minimally different I learned was the rear wiper switch case – the ‘wash’ feature of this 2 stage switch engagement doesn’t work unless the case is filled where others have an opening. I used JB Black Plastic Weld to fill. Life is good and they all easily slide into the UK switch bezel. But of course, when I got in to the XJ to plug it all in I found the connectors to the cigarette lighter and power outlet were different ’99 XJ (which the 4-switch panel came off of) and ’97 (which my Jeep is). I thought I could simply swap the cigarette/ power assemblies, but they have insert ‘teeth’ that were keyed differently than the ’99 switch panel. Finding connectors to make the conversion...'99+ XJ connector at left; '97/'98 XJ at right. Also plugged in a JET Stage 1 chip. I know it’s not going to tune any sort of crazy additional power but it’s good for something (according to Jp magazine they saw +10hp/ 12 lb ft on the ’97 TJ they dyno’d without any exhaust upgrades). And I ran their Stage 2 for years on my ’01 XJ without issue, so why not…

I have a couple Selec-Trac's and can send one if you let me know address

The XJ factory sound system even with upgraded aftermarket Infinity speakers and the OEM Infinity amp just doesn’t sound that good, so I’ll be wiring in the best compact amplifier I have ever found (1.5”x4.25”x6.75”) – the Rockford Fosgate Punch PBR400x4D. I'm wiring it up using standard color speaker wires with Molex connectors that plug right into the amp, nice and clean. Power comes to it via the under hood PDC where I ran new/ extra power lines into the interior for just this purpose. I may or may not run a sub in the Jeep… I have the Mopar spare tire sub which I may gut and run an 8” Rockford shallow sub. The Mopar subwoofer really is a piece of crap. I had one in my ’01 XJ when it was new for a while. The little amp they have in it dies very prematurely and the speaker falls apart soon after – but it’s an ingenious way to tuck away a sub and it fits in even the compact XJ spare tire. The other option is a beautifully crafted aftermarket XJ set up that resides in the passenger side cargo area cubby made by SubThump. It fits a 10” shallow sub and it looks decently OEM, but I’ll have to cut up a spare interior quarter panel. Power for either sub will come from a Punch PBR300x1.

Moving at a snails pace getting the ‘97 XJ together, but had some time this weekend to get the MagnaFlow cat and the Borla muffler/ exhaust system up. I’ve always run Borla on my Jeeps, never any issues and it sounds great. ('97 XJ's with California emissions have two oxygen sensors...one pre-cat on the header and another just after the cat.) Managed to find 2 NOS oxygen sensors for the set up and got them plugged in. I then turned my attention to the 8.25 differential -- emptying it out, and installing a new cover plate, LubeLocker gasket, and bolts. Then filled it up with Lucas synthethic. (I learned this Jeep came with the factory trac-lok, so I look forward to rebuilding it around 150K.) Also got to finishing up the fuel tank -- a new Bosch fuel pump/ sender assembly was dropped in before mounting the tank back up. Next time I tinker on the Jeep I'll mount the factory fuel tank skid plate and trailer hitch. I know a 2wd doesn’t need a skid, but I’m just not a fan of not protecting the fuel tank with a little something more. After that, I’ll turn my attention to the sound system and interior reassembly.

To the drier under the hood? If so, in '94 1/2-'96 the plug is different. Same color wires going to it though. If it's interior side your talking about, the probe that goes into the under dash evaporator (in the black box), yes the wires '92 to '95 are the same. I converted my '92 MJ to the '95 XJ r134 set up.

I bought a nos taillights for $50 because it was listed as an xj light on eBay ... Pete, I think you’re good. Congrats.

Engine done and new beefier crossmember installed! (Oddly enough the factory crossmember was used as a jacking point to lift the vehicle. You would think after bending the $#!& out of it a few times one would stop and see that's not the way to go.) Now on to wrapping up the exhaust setup and fuel tank. Fuel tank proved to be a fun one... Someone had damaged the 'fill stopper' of the tank so had to get creative there fixing it. Since the tank is dropped I'm putting a new Bosch pump in it. Exhaust too had a couple surprises-- the later XJ's used different exhaust mounts at the transmission crossmember and tailpipe 2WD versus 4WD. No idea why they did that. The Borla system had the 4WD style hangers. Other than the crossmember bushing, no NOS could be found for that, so off to the wrecking yard I traveled to take one apart and refresh it. Next up-- polishing the paint and installing NOS fresh body side moldings and '00/ '01 XJ emblems. Agate interior install will finish things off for this build.

I found the 4 switch panel on eBay UK. There’s also guy on eBay in the US who makes something similar but not as nice as OEM.

Chipping away at the XJ... I remembered I had a NOS AW4 cooler I've installed. Radiator went in, new power steering pump/ pulley, hoses, belt, etc.

Nice MJ. Looks good!

Had half a day so finished up some things interior side... I wired in a factory fog light switch (and fog lights) and an 'extended idle' switch using factory connectors and terminals. It took a while scavenging the original terminals off the factory wiring, but the results look great. I re-arranged the order of the switches left to right to what makes sense to me -- fog lights, extended idle, wiper, defroster. Wrapped it all in OEM style fabric tape. These rocker switches will be housed in a factory 4-switch panel. Below is a pic of my original 3-panel versus the 4-panel (still with the UK switches installed). I also learned that 97 XJ and 97 TJ gauge clusters electronically are identical -- only difference is is the design overlay. I prefer the look of the TJ gauges. (Unfortunately this isn't always the rule for other year XJ's to TJ's... Back when my '01 XJ was new I was looking to do the same but the warning illuminations were in different locations. The main difference I see warning light-wise between my '97 and '01 XJ currently is that the '97 does NOT have the 'trunk open' warning). Some pics -- '97 TJ top and '01 XJ cluster below.

I bought that ebay one a while back but from another vendor. Decent quality but the grain in way too coarse to match anything that ever came in an XJ/ MJ.

Even though it's a low milage Jeep, I decided I might as well upgrade/ replace things while I have it apart changing the manifold and exhaust...so I installed new Hesco high flow water pump and t-stat housing, bored TB, K&N intake kit, new harmonic balancer, alternator, HD Mopar radiator, all hoses, gaskets, pulleys, and serpentine belt. Also wired in through the factory engine bay connector an extended idle switch I found on ebay. Since the 97-01 XJ's already have the necessary wire coming from the PCM, I went to the wrecking yard and clipped that same factory connector and carefully pulled several wire female pigtails out and then removed the terminal end to use on the new wire I ran. I then installed the wire into the factory connector located at the back passenger side of the engine and ran it to the dash in a UK sourced 4 switch panel. Next step is POR15-ing the interior floor to prevent possible future water leaks between gaps in panels. Then on to installing the new agate ‘01 XJ interior...then the exterior trim/ emblem refresh.

Don't see these AC delete brackets much, especially on the HO years....but there's a blue 92 XJ in the Pick n Pull San Jose CA North yard that has it. No idea on the cost.

Tinkering back and forth between the MJ and this XJ... Had a couple hours today so I unbolted the factory exhaust, intake manifold, header and downpipe. Going in it's place will be the newer U-shape manifold and Borla header through exhaust system with a MagnaFlow cat. Taking my time on this as I'm replacing a few other items (pully, belt, sensors, and radiator) and need to drop the tank because theirs something I can hear floating/ bumping up against the tank when its full. I have a good hunch that when the TSB replacement fuel pump went in something broke off and the tech didn't bother to fish out. Driving me nuts... Here's the removed parts if anyone is interested in them. I'll post in the for sale. The benefit to this log style intake is the newer 96+ XJ belt adjuster. A hell of a lot more user friendly than the older style.

I've been slowly digging out some NOS purchases from too many years back... I had always planned on buying a second Comanche (the one in this thread), so at the purchase of my first MJ I was essentially buying for 2 of them. '95/'96 XJ doors will soon be mounted up and I can continue with the Beijing window regulator/ '97+ XJ full window conversion in preparation of paint (hopefully summer of 2020). The benefit of these doors is they have the side impact protection inner shell. Aiming to mount these up this coming weekend.

Yep, confirmed it was alternator with a tester...The battery charge is consistent but the alternator both on my instrument cluster and voltage test under the hood is all over the place. Within 15 seconds it goes from 14, down to 9, up to 14 down to 5, up to 14 down to 2 over and over again. Going with Mean Green this round as I have had luck with them in the past.

Took the MJ for a run at the crack of dawn this morning. PCM learned the stroker and ran much smoother after 30 mins. Then my less than 60 miles on it brand new Nations high output top of the freakin line alternator stopped charging. Got about 2 blocks away from the house roadside and I pushed it into a school parking lot. Damn that’s frustrating. So much for made in USA.

I might do that for the longer haul once I get the windows back in. Keeping it to local expressways for now.

They stick out not quite 3/4”. I’ll snap a pic. The xj xj has been sitting too! Driving me nuts! Want to head out early this weekend with the Mj to finally start getting the stroker broken in and didn’t want it to overheat.

Done but they're not permanently mounted yet as I'm going to wait until I paint the truck. Unfortunately/ fortunately, I had to go back to the factory air box as the k&n filter charger kit was too high even if I trimmed the louvers. Volant air intake kit didn’t work either for the same reason. I'm surprised how much I like the look of the louvers. I actually like it better than the XJ cowl hood. For some reason I only think cowls belong on Chevy's.

Getting back to the MJ a bit as I need to take a sanity break from the house project which seems unending... The MJ is going under the knife. Cutting holes in the hood for vents. Here's the before cutting. Currently work in progress so will post again once the vents are dropped into place.

That brackets not needed. I removed it from both my trucks when I installed a beefier crossmember.

TJ and ZJ canyons look slightly (noticeably) different in how they’re slotted.

I run BFG radial t/a’s on my 2wd daily driver xj. 255/60 front 275/60 rear. On 15x7 zj Laredo rims, the fronts are even with the flare and the tears about an inch under the flares. MJs you’d have probably 2” covered but with a 1+” spacer in the back you could reduce that.