RyanL

It is a brand spanking new battery bought one month ago.

I used the donor carpet. Took it to a DIY car wash and pressure washed the tar out of it. Came out pretty good!

Update time! Sealed the doors today, so the insulation, headliner, and carpet all went in! More to come! Stay tuned!

Took the truck for a test drive today after the shortened driveshaft came in. 1) Still runs rough. Will backfire and shudder under load and will slowly spin down and die if idling and the A/C is on. (ever since startup it has run bad we believe it to be a timing problem) 2) 4x4 works except for 4Lo. Coasting, in Neutral, it just grinds and the shifter does not "click" into place. This means the shifter is incorrectly adjusted? 3) With the new compressor on the truck, it only squeaks when the A/C is on. Belt to loose/tight? 4) The horn randomly came on and stayed on until I disconnected them. The Airbag light has been illuminated since the accident the donor had, means bad clock spring? 5) It finally moved under its own power! Which is a step in the right direction! If any of you guys have ideas or comments on the above please answer! Any help is great! More to come! Stay tuned!

Yes the existing MJ holes were used, with the bolts from the XJ on the top hole, and the bolt from the MJ on the bottom hole. The belts are not adjustable, but the divers side seat is electric, so I thought it was kind of a moot point. On the belt mechanism mount, I used an angle grinder to cut the mount where it flanges out into an "arrow" with the XJ bolt hole in the middle of the arrow. Then I marked and drilled a new hole in the mount higher up to make use of the existing MJ bolt hole. Also I don't understand what you mean about the doors. Take pictures of how they are mounted or how to align them?

Both fans operate and the nose of the truck was in a two car garage by itself when it got charged so airflow was okay.

Update time! Got all of the interior in except the carpet. (The doors still haven't been properly aligned). Seat are in as well! Since the engine is running, we also installed the accumulator dryer and charged the A/C system: Two things: The electrical fitting on the top is NOT included on the new Acc/dryer and must be transferred. Second, the mounting bracket and ring are oriented like this: (Took me quite awhile before I figured it out :doh: ) The system has a frightfully high pressure though, and the clutch on the compressor screeches horribly, so it will be replaced here in the next couple of days when the new one comes in and will hopefully fix the problem. More to come! Stay tuned!

Update time! Got more of the interior squared away after work today, the seat belts were cut and installed. To use the 97+ XJ seat belts you need to cut the mounting bracket off right after the bent tabs above the hole. Then mark and drill the new hole and install. It took a total of 20 minutes to do both I believe and they look a lot cleaner than the older ones I think. Also the kick panels are installed The B pillars and back panel won't go in until the insulation/sound proofing arrives, and the carpet won't go in until the doors are aligned properly and the cab is sealed for water. More to come! Stay tuned!

1/4 Dr. Frankenstein moment 3/4 satisfied. Thanks guys!

Updates are here! The console is in (after much finagling and turning the modules this way and that) Oh and THE TRUCK RUNS :jump: Soon gents, soon it will be road worthy! Stick with it because progress is going to pick up speed these next couple of weeks! Definitely more to come! Stay tuned!

Okay so the tests went fine and returned all the expected voltages. Also a closer look at the wiring diagrams revealed that the circuit the orange wire is on goes to all the sensors and since the others returned 5 volts, we re-preformed the CPS voltage test and it came back 5 volts. With ALL sensors and modules unplugged, the only things left on the BUS circuit are the cluster, PCM, and the wiring in between. This means either the PCM is bad, or the TWO clusters we have are bad. Not so far out of reach but still sketchy for sure. With the burn mark on the first and the illuminated blinker flasher on the second I'm not counting my chickens just yet. If the last cluster arrives and checks out and still gives us NO BUS that leaves the PCM because the continuity tests for all CCD bus wires check out. More updates to come.

Well with the new connectors and the first of the new to us clusters that were ordered, we still got "no bus". We tested the voltages to all of the 5 volt sensors and came out with the correct voltages on all except for the CPS. It had 12 volts at the connector. According to the wiring diagrams, it has a five volt input from the PCM. However, the power wire for this sensor is also connected to the ASD circuit, which runs the cooling fan which has inexplicably (until now) been running constantly with the key on RUN. This leads us to believe there is a short on the orange wire on the circuit, giving 12 volts to the CPS, fooling the cooling fan into running on its fail safe, and contributing to the no bus. Either that or the PCM is indeed bad. We are going to run the tests again to be sure it wasn't just a faulty reading, and see where we go from there. Another interesting note is that the cluster we got from the LKQ that arrived first, had a blinker bulb that will not go out (the left blinker flasher was illuminated all the time), and the first cluster has a burn mark. It could also be that both of the clusters are bad, but that will have to wait until the other clusters arrive. With both clusters we still get 60 ohms at the DLC plugged in and 120 ohms unplugged so its anybody's guess until the new ones arrive. I was talking with a good buddy about your problem and he agrees that it sounds like the cluster as well but he did tell me that once, he did have a Jeep that the engine ran with "no bus" and it did turn out to be the PCM. He said that was maybe one out of a hundred that had that problem but almost all of them were the cluster connectors and/or cluster. Personally, the only problem I've ever seen is the cluster and connectors and I've probably seen this problem about 100 times as well. Probability wise, money is still on the cluster so it's definitely a good next step. I learn something new everyday. Let us know how it turns out.

I certainly hope so! 150+ bones and a dealership visit for a flash would not be fun... However, I do want to thank you for your help and swift replies! Solving a problem is ten times as easy with help and different outlooks and I appreciate it! Even though the problem has not been rectified yet (just waiting on parts now) fingers crossed!

After pouring over the research on my lunch break, I found a thread that had been posted on Cherokee Forum, in which a guy had opened up his cluster after doing all the tests we have talked about, and it was burned by the odometer. He replaced it and it solved his problem. To add insult to injury, the Ohm resistance from the DLC to the cluster is supposed to read 120 ohms. With the cluster plugged in it reads 60, unplugged it reads 120. With the truck "passing" all other tests (continuity, modules, etc.) this leads the most likely culprit to be the cluster. More to scratch an itch that anything I opened my cluster up. Lo and behold we have a burn spot in the exact spot his was in: A new(ish) cluster has been ordered, as well as new connectors from the dealership as you recommend. I figure if I'm going to get new pins I might as well cut the option of the connectors being bad out of the equation at the same time and replace both at once. If this doesn't work then it leaves the PCM. Because, correct me if I am wrong but with all modules that interact with the bus (Air bag, overhead module, sentry key, TCU, and DLC) are disconnected or check out with the appropriate tests, the only things left connected are the cluster and PCM. Either the PCM is sending the data and the connectors or cluster are not receiving it, or the PCM never sent it in the first place.

The over head module and BCM was the first thing we tried because that was the only thing we changed on the harness. And the car will start, we discussed and agreed not to start it until we have gauges being that it will be the first start up on a rebuilt engine and if something goes wrong, the gauges could be the only warning in some cases. And the sensors I was talking about were all of the 5 volt modules that feed the bus. We tried unplugging them one by one like you say with no results. We did the multimeter check after trying the sensors one by one and the voltage at the diagnostic connector was normal (between 2.41-2.5 volts on pins 3 to 4 or 5 and pin 11 to 4 or 5). I guess my question is how can we unplug the cluster and know if the bus comes up before we start it to see?

After compiling research, my father and I both performed tests on the cluster, TCU, wiring, and all sensors that feed the CCD bus and after comparing results came to the conclusion that, like you say, it is either a bad female connector (C1 contains the bus but C2 can contribute the error code we have), or an open ground on the dash harness. The cluster was checked using the actuator test, the sensors by unplugging each one and seeing if the error code would go away, and the wiring using the pinouts for the plugs in the TCU and sensors to the PCM. If that gets us nowhere, our next option would probably be to test the resistors in the PCM (simple multimeter test). If all else fails track down a DRBIII tool or send it to the dealership. You might want to check out this TSB. I really doubt you need a PCM or cluster. Instead of wiring on the new pigtail, you can also clean the old connector with electrical contact cleaner and then take it out of it's holder and place it on the other side of the plastic, making it go further into the cluster when you screw it down, works very well too, if that indeed is the problem. We cleaned the contact points of oxidation on the cluster, and tried to tweak the pins a little to connect better in the plug but no such luck. If the voltage tests return negative then a new connector would be the next option.

Well good and bad news. Bad news is, the computer will not give power to the fuel pump to start the engine. The gauge cluster reads "NO BUS", which means somewhere along the line between the computer, gauge cluster and CCD BUS, there is a problem. After ohming out the wiring, it brought it down to the gauge cluster or the computer. Hopefully the problem can be rectified soon to start the truck. The silver lining here is that the truck (minus a few parts) is generally put back together. The engine is done save for the accumulator dryer (to be installed when the system can be charged) And the dash is all in except for the radio, which is waiting on the adapter harness The back steering wheel trim piece is off too because the steering wheel may need to come off in the future, and is not tightened down. There's life in her yet, just need to iron out a few last wrinkles and it will be time to start! More to come! Stay tuned!

Thank you!

Update time! Got most of the engine compartment done today! Only the brakes, air box, and accumulator dryer are left! Front buttoned up for good! Tomorrow the interior goes in and the key will turn! I can't wait! Stay tuned!

The engine is IN! :jump: After a little more elbow grease and some more parts it should be fired up this Sunday! I can't wait!! :clapping: :clapping:

Thank you for the compliments! I know you've been having a lot of problems with your painter and I hope they get resolved quickly! I can't wait to see your finished product, it's going to be a beast!

Update time! Got the fender flares on! And loosely bolted on the bumper to check the fit! Got the cowl and wipers all buttoned up. And assembled the nose piece Then put it on (This has to be my favorite picture so far. It is starting to look like a truck again! :yes: ) More to come! Stay tuned!

Both :laughin:

Now there's an idea. "Rocket 'Manche" :rotf:

Honestly, I never expected to see one up close in real life but my father took a trip to the PAP in Baton Rogue while I was up at college and there was a two door sitting there plain as could be! Talk about strokes of luck. I'm half expecting to get hit by lightning sometime in the near future....