New to us '96 Cherokee

[JZLAJeep]

It happened again, another XJ followed us home over the weekend. I'm a sucker for 4.0 with AX-15 and this was at a price that couldn't be refused.  Had to make a 4 hour drive to northeast Oregon, but the drive was gorgeous and we came home with a Jeep! This makes 4 at the house though (2 XJs, MJ, CJ-7), which is a problem... 

 

'96 model year, Cherokee Sport, optioned like my '95 2-door, 235.5K miles, straight body, dirty but otherwise good upholstery, factory radio/cassette. Cruise works, AC works as much as we can tell in October.

 

Needs some TLC and a deep cleaning of the interior. PO had a Thule box on the roof, but took it off, but left the rack/bracket with no key for it. Will have to decide what to do about that.

 

Seller said he parked it and it didn't start when he came back, pulled a code (since it's a '96) that said alternator. Instead of fixing it he just listed it for sale. We took a battery (borrowed from the MJ) and a new alternator from Amazon and went on a road trip. Hooked up the battery and the Jeep started right up. Took it for a spin, saw the voltage dropping so parked, put the new alternator in and it was ready to drive it home! 

 

Now that we have it, need to decide what to do with it.  Could become the 15 year-old's to drive next year if he helps with it. If not, maybe need to find it a home with someone that appreciates a Manual XJ.

 

Needs (Identified so far):

1. Clutch
2. Oil filter housing o-ring
3. Badly needs an oil change
4. Straighten transmission brace (shouldn't look like an upside down V and the transmission sounds like it rattles when turned on/off)
5. Ignition cylinder and steering column surround (works, but ugly - someone tried to steal it from PO, but apparently couldn't start it or drive stick...)
6. Door latches
7. Center Console lid (gray)
8. Right front corner turn signal indicator
9. Dome light covers
10. Headliner is a little saggy, but not horrible (yet)
11. Hub cap (have one that needs some paint)
12. Sport trim (have some)
13. Rear hatch struts
14. Light bulbs all around
15. Tires are mismatched, but OK for now

 

 

 

[M.T.Hands]

Very Nice

[75sv1]

Not sure of the intent of use. It does look nice. Many of us do look for a manual. Still, the AW4 is a good auto trans. I would try and keep the Thule rack on, if MPG is not a problem. I have sometimes put lumber or other building material up top. The factory one has clasped on me. Still don't like putting stuff up there on some of the roads I drive though. Some have issues with the '96 year. Others, its the best XJ they've had. 

[Pete M]

it happens.  you're just out and about, minding your own business and BAM, there's another XJ in the yard when you get home.   

[JZLAJeep]

2 hours ago, Pete M said:

it happens.  you're just out and about, minding your own business and BAM, there's another XJ in the yard when you get home. 

Exactly! 

[JZLAJeep]

Replaced the clutch and the rear main seal. Gotta brag on my son who took on the task of straightening the taco'd transmission crossmember. Should do the trick! A little extra steel never hurt anything...

 

Before (supposed to be straight in the middle)

 

After

[ComancheKid45]

I loved my 96. I'd love another one day. 

[pizzaman09]

Great project.  I like this vintage of XJ.  If I had a need for an SUV, I'd own one.

[JZLAJeep]

Some updates on this guy.

 

Temperature gauge on the dash hasn't worked since we purchased this vehicle. Tried replacing the temp sensor on the thermostat housing with no change and then learned that was the wrong one. So tried replacing the temp sensor at the back of the block. That turned out to be a surprising pain in the rear... and the gauge still doesn't work.  Should have been a warning sign when I read that the sensor is easier to install if the valve cover is taken off first. 

 

The problem is that the stamped valve cover on '96+ has a vertical lip around the edge that won't let a socket or wrench sit on the hex part of the sensor. I snapped the old sensor off, which was no problem because I was replacing it and figured it was weak, which was why it didn't work anyway. But I didn't realize the valve cover lip was an issue until I snapped the first brand new sensor in half too.  Ultimately ended up buying the cheapest 9/16 wrench I could find on Amazon and cutting it up to make a tool that kind of worked getting on 3-sides-ish of the hex. I got the sensor about halfway in before the corners of the brass hex portion of the sensor started to round enough that I didn't dare to further. I got it in far enough that it doesn't leak, so I considered that victory enough and quit. If the part manufacturer made the brass hex portion of the sensor taller, then this wouldn't be difficult at all. Haven't checked to see if this is as big of an issue on older valve covers.

 

Location of old sensor at back of block

 

Old sensor broken in half

 

First attempt at installing new sensor. Broke it in half. Note the valve cover lip on the back side of the sensor. Once screwed in a little, a socket will no longer fit and are lucky to barely get the open side of a 9/16 wrench on it. But then the firewall and wiring harness get in the way.

 

Cheap 9/16 wrench that I cut up to make a tool to install the sensor.

 

In other news, drove the Jeep to work, came out later and the starter had given up (at work). So got to replace that in the work parking lot the next day.

 

The old muffler had rusted through in a spot so my sons worked on that.

 

Then last but not least, added some Grille decoration this weekend. Bought it used with the Hella lights on it. Haven't hooked them up yet.