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I’ve owned my XJ since I was 18 and always wanted an MJ, 16 years later I’ve finally purchased one. The MJ will be a mall crawler only I won't do anything more than some logging roads. I have the XJ for rocks.
The truck didn’t look horrible but maintenance wise it has been neglected.
Previous owner put a full traction lift and fox shocks on it before I bought it.

9m0arkq.jpg?1

My initial plan was to swap in AC from a parts XJ and paint it.
As I’ve progressed I’ve ran into a number of issues.
PO stuck an antenna through the roof and never sealed it which caused floorboards to rust out.  -FIXED
Clutch MC was leaking which caused more floorboard rot, surprisingly no visible damage to the fuse block but I’m replacing it anyway.  --FIXED
Power steering pump is toast, PS box leaks like a sieve  -FIXED
Tcase output seal
Motor mounts
trans mount
Chassis wiring harness had melt spots  -FIXED
Interior wiring harness was cut up/ ghetto wired in multiple spots. - FIXED

Radiator reservoir (all metal) was smashed in on one side.
Remove ghetto Pushbutton Start - FIXED


In addition to fixing these issues I’ll also be swapping to HO open cooling
eliminating c101 --- DONE
and upgrading the headlight harness. --DONE

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The only thing stock on my XJ is the trans. I'll post a little on it before moving on with the MJ. 

87 XJ 2door, 4.6L, aw4, Atlas 2, D60 ARB , 10.5 Detroit, 5.38's, 41" Iroks, 14" swayaway coil overs, Hydroboost brakes, PSC pump/box , Nickintime REM sensor monitor (Can't stress how essential this is), stuff. 


Here's the stroker parts list for anyone interested https://docs.google.com/spreadsheets/d/1xTunJzocDmT51AIPQOVKN-plp82W3o7mqS9_Ko1n_K8/edit?usp=sharing

Mj5vxJL.jpg

 

 

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AC Swap
I’ve looked thoroughly through the AC and non AC systems. The only thing Jeep left of any use in my non AC MJ was the hole drilled in the relay bracket for the AC relay. If you’re looking at doing this I’d swap the entire wiring from an AC’d XJ ( MJ Evap cores are different). There’s about a foot of AC wires on the engine side of the chassis harness before it terminates, these wires have nothing to connect to on the interior side of the c100/fuse block so it’s pretty worthless.


AC Parts List
Rock Auto
UAC EX9449C Expansion Valve $9.89

UAC HA11332C Suction Hose with muffler (compressor to evap) $27.79

UAC HA111331 Discharge Line (High Pressure: Compressor to Condenser $18.87

UAC RD9086C Drier $13.50

26758 Four seasons Oring set $5.69

Optional-ish
93024 Heater Core Spectra Premium 30.79

Jeepair.com
Cherokee Liquid Line Drier to Condenser 27-5551 1 $43.99

Cherokee Liquid Line Drier to Evaporator 27-5552 1 $39.99

Amazon
UAC EV 4177ATC A/C Evaporator Core 70.00
Spectra Premium 7-4173 A/C Condenser for Jeep Cherokee $77.57
Four Seasons 58580 Compressor with Clutch $175.00

RedTek oil $15
RedTek refrigerant (formerly known as R12A) $30.00


Total $529

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I purchased an 89 parts xj from what I've read in other AC posts Evap cores for MJs are impossible to find. 
The Heater box fit right in but the but the evap core didn't quite fit I had to cut away some of the plastic the hoses pass through and cut the foam seal.
The hoses on the evap core are vertical instead of angled like stock jeeps. 
Also the AC switch probe has a hole for it on the stock core the replacement does not. I wrapped it around the side and pushed it through the middle. 
cRcjmdN.jpg

Not really too much to talk about here, I'll need a vacuum diagram or maybe I'll just go to the JY since my MJ didn't have the vacuum reservoir I need to know where things go. 
Other than that there's a crap load of wiring to deal with. 

DJlE7MT.jpg 

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5 minutes ago, eaglescout526 said:

You've piqued my curiosity, What years and engines do those lines fit?

The rockauto ones are listed from 80-90 the jeepairs are listed as 91+ though I've seen them posted here as fitting renix. I'm not a huge fan of going blindly off forum posts but we'll see. 

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Ac is on hold until I finish with the steeringbox/pump since It's really easy to get to right now.
CIBzkCA.jpg

Today I deleted the C101
I highly recommend doing this one wire at a time and paying attention to which ports they come from. Some change colors, some terminate in the connector. No sense in leaving room for error. 
I'm surprised anything connected through this mess. 
sCwhDAE.jpg

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Make a build thread for that XJ in the Other cool stuff section please!!

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2 minutes ago, 89 MJ said:

Make a build thread for that XJ in the Other cool stuff section please!!


I've thought about it, it's never really had a home thread. There's just so much to cover. I might if I get bored. 

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4 minutes ago, m2bandit said:


I've thought about it, it's never really had a home thread. There's just so much to cover. I might if I get bored. 

Please get bored then. :D:wink:

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The drivers side rust came from both the clutch MC and the roof leak. The first picture is a massive hole right over the fuel lines I had to weld up. 
I wrapped them in welding blanket, removed them from their clips and pulled them away with a strap as much as I could. 
Nothing exploded so we're good.
ULbd5Pm.jpg
I didn't get a picture of the rust from the MC but it was everywhere the sealant jeep used on the floors did a good job of holding it underneath so it couldn't drain away. I'd be willing to bet anyone that had to replace their fuse block/c100 has hiding rust holes. 
stRV47M.jpg

Passenger side  before and after patch, I should have ground it more flat but I was impatient that day. I kept burning through the floor with .30 wire, I'm sure being weakened by rust wasn't helping.  I wirebrushed/flap disced everything to metal and sprayed it with rust reformer. 
96UFIrN.jpg
4dcGsaC.jpg

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Well the entire AC system is in, it's sitting under vacuum right now and appears to be holding. 

D0Fqkho.jpg

A couple notable mentions. 
1st, the AC heater box has a drain spout in the bottom. The Non AC MJ does have a plug for it you just have to remember to remove it. Luckily all of my cussing getting the heater box in didn't damage the box and pushed the plug out of the way. 

2nd, The drier has this fitting cluster F... attached to it. It does not come with the new hoses or the new drier.  So there's an Oring I didn't get to replace it's inside the fitting and requires a dental pick. IjNa0bH.jpg


New steering box and pump are in, engine harness is back in. 
Just need to reinstall the dash, interior wiring, and cooling system.

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Heh. Just got off that boat. Miniut gave me a good tip, said to crank the compressor over about ten times before charge.  

 

That dryer location makes me appreciate the location for the 2.5's a little more.

 

Good luck!!:L:

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3 hours ago, eaglescout526 said:

Heh. Just got off that boat. Miniut gave me a good tip, said to crank the compressor over about ten times before charge.  

 

That dryer location makes me appreciate the location for the 2.5's a little more.

 

Good luck!!:L:

You all done with yours?

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