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steph74
11-04-2010, 09:32 AM
Well i am not going to build a rig like some of you guys, I just want to make it running good to have a little fun when going to the mountain and occasionally joining on a rock trail or mud trail.
So don;t be expecting a lot of crazy mods and extreme wheeling pictures ;)

So this is my humble project that I got to learn stuff and not feel like an idiot everytime I go to a mechanic.

If you are asking what the h@ll is Vercingetorix - Wikipedia, the free encyclopedia I would refer you to the wikipedia page but in substance he was a great Gaule warior chef that defeated the Romans a couple of time back in the day ;)

So I got this beater jeep a while ago and started slowly making it run good.

I still have a lot to do, little money to spare and LOTS to learn.
Most of it I have done on my own and I am pretty proud of it ;)

-Bastard pack on the rear to remove the cracked blocks
-changed rear brakes
-fixed most of electrical gremmlins
-Changed a cracked radiator (thanks to Mike)
-cut the hood to put cool looking hood vents
-got rid of the low idle, and knock
-changed motor mounts and transmission mount
-started painting it by little pieces
-did a total overhaul tuneup
-learned how to check and locate all the rennix sensors
-put a cat and muffler
......
-What I need to do....
change some of these sensors that are misbehaving at times
overhaul of the front brakes and maybe change the brake lines all around
a couple of seals that are leaking slightly


In the end I am having fun learning and that is all that matter to me

The day we got it... the Team... good to have little handed helpers
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335597505517_544930517_4172735_4422530_n.jpg

Tackling the tune up... first time so trying to figure out what is what
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631160517_544930517_4172973_6507163_n.jpg

The body was in good condition for a 21 year old jeep
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631180517_544930517_4172974_10340_n.jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631195517_544930517_4172975_5638991_n.jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631220517_544930517_4172976_3180314_n.jpg

The engine looked clean and scary at the same time
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631270517_544930517_4172979_1446015_n.jpg

Inside was OK just a couple of wires running everywhere that seemed to be part of a stereo system I removed all of it and kept only the 2 front speakers.... got a $2 radio at a second hand store and fit it in it...
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631280517_544930517_4172980_7535833_n.jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631310517_544930517_4172981_3256973_n.jpg

Comment from my wife for this photo... "I bet this is how I am going to see my husband for a while"
http://i1195.photobucket.com/albums/aa381/stephaneb74/24800_335631445517_544930517_4172992_5812067_n.jpg

First trail outing with guys from Utah.... had fun but broke the radiator 2 miles into it....
http://i1195.photobucket.com/albums/aa381/stephaneb74/38967_10100475993961101_2061436_70365650_4371306_n .jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/38792_10100475993941141_2061436_70365649_1360541_n .jpg


Second outing by myself... everything went smoothly other than the horn beeping at everybump by itself and the front brakes driver side rattling like crazy.... she did good and I had some fun.... all what it was intended for...
http://i1195.photobucket.com/albums/aa381/stephaneb74/183174681.jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/183172203.jpg
http://i1195.photobucket.com/albums/aa381/stephaneb74/183171118.jpg

4.3LXJ
11-04-2010, 10:21 AM
Are you gonna paint it Yellow?

steph74
11-04-2010, 10:24 AM
yes yellow with black 1/4 panels and 1/2 fenders (spray pain crappy job but it doesn;t matter I'll do better for the next one)... I wanted camouflage... but I gave up to the family wishes...

4.3LXJ
11-04-2010, 10:28 AM
So far, the tailgate looks good. I like the color. Kind of unique. If you stick with the yellow and black theme, you can call it Tonka Toy

Before you get too far into it, Caterpillar makes some awesome spray paint, tough stuff for rattle can.

steph74
11-04-2010, 10:38 AM
thanks for the advice... I already have my spray paint though just couldn;t find the time to finish it...
Black is rustoleum bedliner spray paint... just did a small patch to see how it hold... and so far it resisted good to the wire brush test (tried to scratch it with a wire brush... barely shows marks)

cantab27
11-04-2010, 12:26 PM
top job mate ... thats how we all learn , doing it ya self ...

steph74
11-08-2010, 03:37 PM
OK so anyway I have tons of question and decided the best place to discuss them were on this thread. (please let me know if you think it is inappropriate)

lets start with CB issues. I have read plenty of tutorials and cool sites on how to install /tune CB antenna. My antenna is not tuned.... but I have some weird stuff happening. Lots of noise and poor reception (OK antenna tuning would probably solve most of it right ?) but I installed a noise reducer thingy and now when I try to talk, it increase rpm (weird ? i removed it but wanted to know if anybody had an idea as to why ?)

steph74
03-13-2011, 09:34 PM
Today I decided to go with the fender triming.....
I kept the original fender flares but cut them a little...
I also sanded primed and bedlined the chrome bumper ... I hope it will last a bit because it is a chore to sand chrome ;)

still waiting for spring and warmer temperatures to paint

http://i1195.photobucket.com/albums/aa381/stephaneb74/624db276.jpg?t=1300069799

http://i1195.photobucket.com/albums/aa381/stephaneb74/a4ee6c52.jpg?t=1300069798

http://i1195.photobucket.com/albums/aa381/stephaneb74/64179806.jpg?t=1300069798

cantab27
03-13-2011, 09:52 PM
nice work steph.....trim looks good (better than ya rugby team..)

alwaysxj
03-13-2011, 11:26 PM
looks good steph. we should just build you a front and rear bumper and paint them black...

4.3LXJ
03-13-2011, 11:41 PM
Nice work Steph

steph74
03-14-2011, 02:05 PM
looks good steph. we should just build you a front and rear bumper and paint them black...

Beware, one of these day I am going to take your word for that ;)
You still have your rear bumper ?

Question, do you have an impact wrench or something, I want to remove the Hitch but it is too tight for me ?

How is the baby doing ?

alwaysxj
03-14-2011, 02:11 PM
Beware, one of these day I am going to take your word for that ;)
You still have your rear bumper ?

Question, do you have an impact wrench or something, I want to remove the Hitch but it is too tight for me ?

How is the baby doing ?
I would be happy to help you build a bumper.
I sold that one and built a new one.
yes I have one with a compressor come on over and we will get it done.
she is doing good. thanks for asking.

steph74
04-01-2011, 12:09 PM
OK so now I am at the point where I am going to gather information on how to change the head and head gasket ;)

Got a junk yard head the other day. It is definitely a fun little job...Casting #2686 is the correct model for my jeep since it appear that they are different according to the years.
So keep that in mind...

So anyway I am hoping to get some pointers and tricks to make it easy for a total beginner that is maybe trying a job too big.

I need to take it to a shop to have it checked for straightness and cracks.... That much I know....

Most likely have a valve job done. Should I try to keep my valves or should I use the ones that came with the head I got ?

I have basic auto tools, I am planning on getting a good torque wrench

I have time (it is not a DD) and can use my garage to spread stuff around and do the job over several days if needed.

I need to buy a head gasket and new set of Head bolts. Any comments on what are the better products around here and why would be great.

I know I need to take my time and label everything. I have a Chilton and a Haynes and another manual but they are not all that clear;)

Is there anything that should be changed or replaced or checked while I am at it ?

So when everything is going to be ready.... I'll get to it, take plenty of pictures and post it away ;)

4.3LXJ
04-01-2011, 01:25 PM
Steph

As far as the valves are concerned, let the auto machine shop advise you on keeping them or not. Unless they are cracked or something, they just grind them. A three angle valve grind is nice, a little more hp but costs more too.

If you can, take the intake and exhaust manifolds loose and move them just a little to the side. An 1/8" is good enough and don't mess with them if you don't have to. Take some pics for your own reference. A very wide wood chisel is good for scraping off the old gasket from the block.

xj4life2
04-01-2011, 03:15 PM
i agree with Steve I have found that pictures (digital) can be a lifesaver. Seperate storage areas labeled for parts, nuts, bolts ect ect. egg cartons make great storage containers as you can lable the inside top. As for gaskets check with the machine shop sometimes you can actually get a better deal from them than a parts house. I prefer Felpro over any of the competition. Pictures of the vacume hook up are a good idea also .

steph74
04-05-2011, 12:36 PM
Looks like I am in for a lot of learning....

As stated before, i want to do as much as possible for the cheapest way possible.
I have called 4 different shops around town and the average quote for taking care of the head, with a valve job is $250-$300 and that is not an option since I have found a complete head online with free shipping and free shipping label to send the core head for the same price...

SOOOOO I have decided to get my hands and Haynes book dirty ;) and attempt to do it myself.

What I want to do is
1/ clean good the head, remove valves and stuff and send it to check from weaknesses and that should be more like $50 at the most)
2/lap the valves. i have found plenty of video online that explain in detail how to do it
change the seals and inspect carefully each component and replace only what needs to be replaced. I already got a thick glass plate from the lab to check for straightness.
3/go lite a candle so that I don;t ruin anything
4/put everything back together.

I am a bit worried because I find it to be fairly easy and straightforward.... and that is never a good sign for me (i perform better under stress lol)


I know it is not the best situation and a lot of you will chime in and say that I should just do it right the first time lol but on the other hand I will never learn if I don;t try....

Soooo I will take the opportunity to take plenty of pictures of the process, I will hope that people here will comment on them and correct what was done wrong.... and maybe that will help someone else that is reluctant to pay $300 to have it done professionally...

So Stay tuned

cantab27
04-05-2011, 02:14 PM
good on ya steph.......only one way to learn....

rguignard
04-05-2011, 03:37 PM
ok steph was that 300 just to do the head or do the job of putting it on ? if its the whole job thats not bad but if its only the head i hope they kiss you first :D the hard part is the clean up of all the parts that sucks !

steph74
04-05-2011, 03:41 PM
well and there is my limitation of talking to people on the phone... I don;t know the exact terms so I may have explained what I wanted badly... or they didn;t want to understand.

I said that I had a cylinder head out and needed it checked for straightness and magnafluxed and a basic valve job....
they all came with that price...

but I am kind of happy and excited to the idea of playing a bit... lol I didn;t get to play with cars before so....

4.3LXJ
04-05-2011, 09:45 PM
Go Steph I started out under a shade tree too on a engine I pulled out of the woods

steph74
04-06-2011, 01:18 PM
So be it ;)

thanks all for the encouragements.
You have no idea what you are unleashing lol.... get ready for the rain of questions....

Yesterday I started stripping the head from the valve.... took me a minute or 2 to figure out the process but I am a pro now lol. here a couple of pictures....

Removing the valves
http://i1195.photobucket.com/albums/aa381/stephaneb74/db41c77a.jpg?t=1302113496

2 advices that I got are pictures... and organization. Apparently an egg box is perfect for keeping together all the parts so...
http://i1195.photobucket.com/albums/aa381/stephaneb74/36d03611.jpg?t=1302113496

Seen on some tutorials, I used a magnetic rod to pick up these keepers....
http://i1195.photobucket.com/albums/aa381/stephaneb74/3496e7b5.jpg?t=1302113496

Tonight if time allows, cleaning.... got a bunch of carb cleaner and engine degreaser. Time to get dirty


Here come the first questions....
From reading, valves are supposed to move freely up and down.... 2 of them were really stuck and difficult to move out but they look straight and undamaged except for the carbon deposits and a little bit of pitting on the seal... they were dry too... could it be from lack of lubrification?

4.3LXJ
04-06-2011, 01:21 PM
Steph, diesel fuel or kerosene is cheap and easy for the first pass. Get yourself a parts cleaning brush too, and a small wire brush.

The valves should not be too easy to move, slightly firm. If too loose, the guides should be knurled or preferably replaced

steph74
04-06-2011, 01:34 PM
Thanks I will go get some diesel fuel then I didn;t think about that...

How would you go to clean the inside of the head ? Can i soak it in something ? or just try to brush inside as much as I can ?

4.3LXJ
04-06-2011, 01:49 PM
You mean the carbon deposits in the cylinders or inside the water jacket?

modestmar00xj
04-06-2011, 03:01 PM
yeah cool jeep man!

steph74
04-06-2011, 03:21 PM
You mean the carbon deposits in the cylinders or inside the water jacket?

well both I guess, I was thinking spraying some carb cleaner in the chambers (not sure it is the cylinder... the part that is above the valve that open to the exhaust/intake ports...)
can I use some LCR (Lime Rust Calcium thingy they sell for bathrooms) to clean the water jackets ?

4.3LXJ
04-06-2011, 03:23 PM
Just do a radiator flush when you install it. The carbon can be removed with a wire brush or scotch guard pad on a drill

steph74
04-06-2011, 03:43 PM
Cool thank you....
yeah flush was in the plan after reinstall because of the nasty water I had to put in after I lost my coolant...


OK So I went shopping around for the head gaskets bolts..... got a good laugh out of it.
Non of the autoparts have it and the guys at O'reilley called the dealership for me to ask about price and availability.... guys sit down....
set of 14 bolts was close to $300
taken from a Forum

"newsflash!
THIS WILL BE EXTREMELY VALUABLE INFORMATION FOR ANYONE PONDERING WHAT TO DO ABOUT 1986-1996 CHEROKEE 4.0 242ci CYLINDER HEAD BOLT REPLACEMENTS:

the ONLY manufacturer of cylinder head bolts for these years is:
ENGINEQUEST
part #HB259N
$38.55 per set
with HEX drive (thank you !)

available through several parts houses (do engine search)
or
https://parts.aaeq.net/
800-426-8771, ext.232 for Sales Department
or 702-649-7776

price is $40 for the set

i'll see how it goes ....

Mudderoy
04-06-2011, 04:21 PM
This is great useful information. Thank you for taking the time to capture the images and post up what you are doing.

4.3LXJ
04-06-2011, 08:24 PM
If you really want to get fancy, you can get studs from Summit Racing too that are race quality.

steph74
04-07-2011, 08:07 AM
no, not fancy ;) just cheap, efficient and safe....
Thanks for the info though. I know that Summit Racing came up several times in the discussions I have read to get the studs/bolts
And to be even more informative, Fel-Pro makes sets of bolts for the heads too I believe for later models though

And I have found this web site to be pretty interesting too headbolts.com
http://headbolts.com/Jeep-AMC-232-244-258-4.0-engine-head-bolts.html

LizardRunner
04-07-2011, 08:42 AM
Sounds like your having a great time learning. Carry on, and the pics are great. Thanks for that bolt site link, I didn't know about those guys.

steph74
04-11-2011, 09:42 AM
OK, I am almost done cleaning the head.... jeeze now i know why it cost that much ;)
I didn;t take pictures during the process because well grease grimmy dirty hands don;t mix well with electronic...
And the jeep is drying in the garage ;) considering the weather I figured I would enjoy a dry place to work on it ;)
I will label everything slowly this week and take pictures and hopefully next WE I will have more time to dig...

anyway I have more questions...

Gaskets: Is the gasket set sold by fel-Pro a good choice ? I believe it comes with head gasket, valve cover gasket, valve seals, thermostat housing gasket, and I belive EGR and TB gaskets ...

Injectors: I am assuming that I will have to remove the injectors during the process (the donor didn;t have the injectors in so I didn;t have to wonder)
That means cheap insurance by replacing the o'rings. Is that really the only thing I should replace if I have to remove the injectors ?

Anything else you guys think i should pay attention / replace anyway while doing that ?

4.3LXJ
04-11-2011, 10:01 AM
Fel Pro is a good choice. Make sure you use those new valve seals. That will keep it from smoking when you let off the gas. You should be able to remove the whole rail if you want.

steph74
04-17-2011, 12:35 PM
OK people the show has started lol... I have spent part of the day yesterday to remove the head, clean, reassemble the head.

This morning I am putting it back together.... I will post pictures

I am stuck at lining the head with the gasket.... any trick now would be much appreciated

Mudderoy
04-17-2011, 12:41 PM
OK people the show has started lol... I have spent part of the day yesterday to remove the head, clean, reassemble the head.

This morning I am putting it back together.... I will post pictures

I am stuck at lining the head with the gasket.... any trick now would be much appreciated

Well I was just searching for some pictures. Seems like I remember metal pegs on my Chevy 327 but I don't see anything like that on the 4.0L.

Have you tried getting a come-a-long and hanging the head over the block and lining it up that way?

Maybe there is something you can put on the bottom of the gasket that will keep it in place but not cause a leak later.

steph74
04-17-2011, 12:44 PM
and that is the problem.... I read that you should not use any kind of sealant on the head gasket....
and because of the lip on the firewall, it seem that the head can enter only at an angle with the farthest bolt already in because it is too tall to be placed afterward....

and that thing weights at least #50 lol I got my morning work out ;)

4.3LXJ
04-17-2011, 02:58 PM
You will start to look like your avatar:D

modestmar00xj
04-18-2011, 01:00 AM
You will start to look like your avatar:D

hahaha!

good job guys! your really attacking the job! looks good so far!

steph74
04-18-2011, 08:12 AM
So this is it....
I took a last good look at the engine bay
http://i1195.photobucket.com/albums/aa381/stephaneb74/e6e97271.jpg?t=1303131543

Then started draining fluids (coolant and oil)
http://i1195.photobucket.com/albums/aa381/stephaneb74/351d8941.jpg?t=1303131543

Then started taking details pictures of vacuum connections, hoses, and stuff at different angles. Labelling plug wires, injector wires, connections etcs.... I passed on labelling the vacuum harness but that is because I changed it before and I have a good diagram of it.... and I am lazy too

First step
off the air cleaner assembly:
http://i1195.photobucket.com/albums/aa381/stephaneb74/e5e60d28.jpg?t=1303131716

Then the fittings on the rocker arm cover
http://i1195.photobucket.com/albums/aa381/stephaneb74/e9eea180.jpg?t=1303131716

and the valve cover itself
http://i1195.photobucket.com/albums/aa381/stephaneb74/204067a3.jpg?t=1303131716

Yuck.... apparently the cover has a precured gasket that is reusable.... well I didn;t read too carefully and since the gasket set had a new one I removed it... oh well
http://i1195.photobucket.com/albums/aa381/stephaneb74/8be9bba0.jpg?t=1303131716

then off the rocker arms and the push rods
http://i1195.photobucket.com/albums/aa381/stephaneb74/e15358b8.jpg?t=1303131716

They have to be put in the same exact position so I used a box to store them:
http://i1195.photobucket.com/albums/aa381/stephaneb74/282f17af.jpg?t=1303131716

Then off the fuel rail and injectors... don't forget to label ;)
http://i1195.photobucket.com/albums/aa381/stephaneb74/e25e4352.jpg?t=1303131716
unbolt the rail and rock it up and down gently while pulling.
http://i1195.photobucket.com/albums/aa381/stephaneb74/ccfbcc6f.jpg?t=1303132046

steph74
04-18-2011, 09:37 AM
you didn;t forget to relieve the fuel pressure before you tried to remove the injectors right ? (this is done easily by opening the gas tank cap and pushing down on the little valve just before the regulator)

Anyway off the throttle body and the heat shield plate.... The books recommended to disconnect the throttle cable. I didn;t because I have a manual so less cable (and I couldn;t figure out how to disconnect the cable)
http://i1195.photobucket.com/albums/aa381/stephaneb74/dd2d3b81.jpg?t=1303136083

then unbolt the manifolds.... exhaust and intake on my year model share the same gasket and they have to be removed together.... top bolts are easy... bottom bolts are... well let's say that you need to be creative with wobbles extensions and small hands and arms....
http://i1195.photobucket.com/albums/aa381/stephaneb74/91f0034f.jpg?t=1303136083
look at this thing.... some bolts were completely lose and the rearmost stud was missing...

And I didn;t take pictures of that but you have to losen the power steering pump, remove the belt and unbolt the bracket from the intake manifold....

Did I mention you need a good manual ? this is the Haynes...well used....
http://i1195.photobucket.com/albums/aa381/stephaneb74/761cc9fb.jpg?t=1303136083

Then get to the left side of the head and remove the 2 bolts that are holding the A/C compressor to the head,
http://i1195.photobucket.com/albums/aa381/stephaneb74/e944598a.jpg?t=1303136083

and also the bracket that is there I think to hold the coolant system hoses away from the head....
http://i1195.photobucket.com/albums/aa381/stephaneb74/a335ae32.jpg?t=1303136083


You are almost there....

Unbolt the head... 14 bolts, they are on tight.... I used a long cheater bar
http://i1195.photobucket.com/albums/aa381/stephaneb74/6d40da1f.jpg?t=1303136083
Remove the ground strap from the rear bolt, unplug the coolant temperature sensor

Then remove the head.... it is heavy... be smarter than me, get someone to help you lifting it off so you don;t break your back....
I left the rear right bolt in because well you can;t really pull it off because of the lip on the firewall...
http://i1195.photobucket.com/albums/aa381/stephaneb74/ef76a389.jpg?t=1303136083

and admire your work....
http://i1195.photobucket.com/albums/aa381/stephaneb74/ccee75e2.jpg?t=1303137440

steph74
04-18-2011, 09:41 AM
Take a break... I started putting the head back together...
new valve stem seals, new studs
http://i1195.photobucket.com/albums/aa381/stephaneb74/93e897a5.jpg?t=1303137060

All cleaned
http://i1195.photobucket.com/albums/aa381/stephaneb74/6f70b8d7.jpg?t=1303137060
http://i1195.photobucket.com/albums/aa381/stephaneb74/eee4056a.jpg?t=1303137060

msmoorenburg
04-18-2011, 09:45 AM
post some pics of the head gasket let's see where it blew

steph74
04-18-2011, 10:02 AM
Then put everything back together in the exact inverse order you removed it.... (that is the stupid instructions from the book lol)

This is the gasket set I used. came with head gasket, valve cover cork gasket, throttle body gasket, thermostat housing gasket, EGR valve gasket, exhaust/intake manifold gasket and valve stem seals
http://i1195.photobucket.com/albums/aa381/stephaneb74/619cb33c.jpg?t=1303137060

I didn;t take pictures of the reassemble just the parts that gave me trouble ;)

Trouble one:
Lining up the head on the gasket.... it is heavy, it has to come in at an angle, the gsket keeps sliding.... all in all, almost 2h of bitching....
http://i1195.photobucket.com/albums/aa381/stephaneb74/3f2ee33a.jpg?t=1303137060

then remember when i said that the rear most bolt didn;t fit ? I should have applied that to myself... after finaly lining up the head, I realize I didn;t put the bolt in...
http://i1195.photobucket.com/albums/aa381/stephaneb74/76eb07cf.jpg?t=1303137060

did it again, with the bolt tapped in
http://i1195.photobucket.com/albums/aa381/stephaneb74/05c3314f.jpg?t=1303137060

Put the bolts back in... after checking you can reuse them once... so since there was no paint on them, I decided to reuse them and save some money (or not but let's be crazy and take risks)
Bolt number 11 (the right front one goes through the water jacket so you have to use some thread sealant. Book recommend locktite 592... couldn;t find it so this is what I used
http://i1195.photobucket.com/albums/aa381/stephaneb74/59a02f45.jpg?t=1303137440

Head is on, bolts are torqued... I rented a torque wrench from o'reilly
Step A 23 ft#
Step B 45 ft#
Step C 110 ft# for all bolts except #11 (the one sealed 100#)

Put everything back it is fairly easy...

lessons learned the hard way:
-don;t forget to put the valve cover in before the thermostat housing
-don;t forget to put the thermostat in before you torque the thermostat housing bolts
-but the belt back in and tighten it before you put the air cleaner assembly because you need to reach the back adjusting bolts on the power steering pump.
-using vinyl gloves as baggies to keep the bolts together is a bad idea... bolts falling in the fingers are more frustrating to retrieve...

Refill the coolant and oil and start it

All in all, it was a nice learning experience, there is always that split second when you try to start it where you hope you put everything back properly and the engine is not going to leak or stuff...

As far as I could see I made only one quickly fixed mistake in my vacuum connection that made the engine run like crap and die as soon as I was letting off the gas.

With time, basic tools and a lot of patience, I would say that anybody can do it

steph74
04-18-2011, 10:04 AM
The gasket was not blown.....
so why did I do that ? well the bolt housing on the thermostat housing was broken and my cheap RTV/quick steel repair didn;t do the trick...

bluedragon436
04-18-2011, 10:38 AM
I was thinking that it wasn't a blown HG for your tear down... almost forgot about the broken bolt...

oderdene
04-18-2011, 08:28 PM
very nice write up. thanks a lot

steph74
04-18-2011, 10:11 PM
very nice write up. thanks a lot

Thanks, I wouldn't call it a write up just a modest testimony that anybody can do it.
I am left with probably more questions than one can imagine lol

So get greasy people it is fun ;)

steph74
05-01-2011, 09:30 PM
It was nice this week end so I played a little...
Disconnected the Swaybar..... wanted intitially to make a quick disconnect like this guys shows how to....
http://www.lunghd.com/Tech_Articles/Suspension_Steering_Axles_and_Brakes/Homemade_Swaybar_Discos.htm

OK he is warning all over this page that th top stud will break...... so obviously i broke mine ;)
Since it is not a DD, and here in the valley there is not really highways around to speed up, I will leave them disconnected, time for me to find a CHEAP replacement solution.

But in the meantime, I took some pictures ;)

I know poser pictures but I can;t go too far away from home until I fix the cooling system ;)

http://i1195.photobucket.com/albums/aa381/stephaneb74/3f1bd91e.jpg?t=1304303166

http://i1195.photobucket.com/albums/aa381/stephaneb74/e4345f50.jpg?t=1304303166

http://i1195.photobucket.com/albums/aa381/stephaneb74/5a7d1e32.jpg?t=1304303166

http://i1195.photobucket.com/albums/aa381/stephaneb74/c90f9207.jpg?t=1304303166

4.3LXJ
05-01-2011, 09:40 PM
Don't worry about the poser shots. You have been doing stuff that doesn't show lately. Glad you got it running and had a little time to play.

alwaysxj
05-01-2011, 10:59 PM
steph we really need to get the jeep painted... looks like it is coming toghether for you. time to go on a trail with me.

steph74
05-02-2011, 08:01 AM
Thanks
Yes I have to figure out bumpstops first because as it is now, the rear rub very easily and I believe it is because of lack of bumpstops ;)

cantab27
05-02-2011, 01:22 PM
have you done anything to help ya heating problem.....mine boiled last two times out wheeling,,,,nice shots steph cheers mate,,,,,

steph74
05-02-2011, 02:18 PM
Not yet,
I realized that the cap on the coolant reservoir overflow whatever this big thing is... was cracked and I figured that would be a big contirbutor in the problem ;)
(I still have the closed system)

So I will try to replace it.

At the same time I am looking at replacing some of the hoses that look old and the water pump that start making chirping noises....

And I need to learn to be patient when refilling coolant and do it slowly like the book says with the added trick of burping the system....


You know what your problem is ?

cantab27
05-02-2011, 02:21 PM
yep..........its a pos,,,,,,,no idea at mo....winter here last time it boiled was hot as hell out

4.3LXJ
05-02-2011, 05:32 PM
It is probably just full of mud Wayne :D

steph74
05-02-2011, 08:53 PM
Here, some more stuff that shows ;)
Got them in the mail today .....
Now I really have to paint it.....

http://i1195.photobucket.com/albums/aa381/stephaneb74/cc69cd2c.jpg?t=1304387423

http://i1195.photobucket.com/albums/aa381/stephaneb74/2ba84a66.jpg?t=1304387423

XJ90TD
05-05-2011, 09:01 AM
Hey Steph. When are you going to paint it ? I can't wait to see the result. For my part, i have to finish mine (red-orange-brick or something...), in the weeks to come. A lot of work though...

steph74
05-05-2011, 09:05 AM
I have the paint in the garage.... it is still too cold and raining here to do that yet and expect getting a good job (not that I have great expectations on my skills lol)

A couple of weeks and temperature should rise enough to allow it... I am excited to get started...
But I have a bit of body work to do ;) to mask my mistakes lol.... self-tapping screws are so easy to use, I put holes everywhere now I have to cover up ;)

steph74
05-05-2011, 09:11 AM
OK so far no boil over ;)....
I replaced the cap on the coolant recovery bottle.... looks like these little buggers are not super resistant....
Doesn't mean I am safe and that everything is working good lol because well it is still not super hot here.... we will see during summer in the mountain

Wayne, how is your radiator cap ? I know that if they cannot hold a good pressure, it will definitely boil over... you may want to check if you have not, it is a really cheap fix

XJ90TD
05-05-2011, 09:27 AM
same kind of problem here, especially the left rear door. It is such in a bad state, that i'm thinking of purchasing a new one on the used market. Later, i will post a photo. But your xj will be a good looking jeep, painted yellow with its black wheels.

steph74
05-05-2011, 09:29 AM
I hope so.... my idea is this color scheme actually yellow with some black...

look at this one, I am sure you would love that
http://www.xjtalk.com/showthread.php?t=7015&highlight=short

XJ90TD
05-05-2011, 10:16 AM
awesome. i like the black rear fenders. I gives me some ideas. The way this guy decided to improve his xj, is really cool. The unique comon point between his cherokee and mine, is the cb antenna mount !

steph74
05-05-2011, 10:23 AM
you should totally do that.... black and orange/brick would look cool.... it is bedliner.... can you find that easily in France ?

XJ90TD
05-05-2011, 10:53 AM
Unfortunately not.... and it's also pretty rare to see these sorts of colors on a cherokee :crazy: A few are orange, but that's all. So you say that it's bedliner ? I thought it was only a simple painting :pray:

steph74
05-05-2011, 10:57 AM
Well here we have bedliner in spray can and it goes on just like a spray paint.... and this is what i am planning to use
Other use the roll on kind either way I am sure you could find it but it might be pricey for sure.... the advantage, it is supposed to protect the lower parts a little better from scratches

XJ90TD
05-05-2011, 11:36 AM
I think i know what it is. Here in France, we call it "Blaxon". It's very coarse, and i put a bit of this product on the trunk floor, because it was starting to rust. But it must be difficult to make a thin layer.
Now i understand, this is not only for the look.

steph74
05-05-2011, 11:47 AM
actually thinking that "Blaxon" is a little different..... bedliner is rubberized I don;t think Blaxon is

steph74
06-13-2011, 02:51 PM
I keep working on the jeep ;) slowly making my way to learning and discovering new stuff.... trying my skills at mild fabrication, I present you.... the all crooked EMT roof rack l0l

good thing is because I followed 4x4Dalton idea, it is all bolted and screws so I can replace sections easily.

I still have to paint but my legendary impatience made me go for it lol....
http://i1195.photobucket.com/albums/aa381/stephaneb74/762616e4.jpg?t=1307993952

I am 300lbs and I can hang from the side of the jeep and it doesn;t move too much
will be stronger when i had a 3rd cross bar I am sure.

http://i1195.photobucket.com/albums/aa381/stephaneb74/4019b3ff.jpg?t=1307993951

I found the gutter mounts at a second hand store for $2... they were from a ski rack that I cut off and screwd a EMT bar onto it.

http://i1195.photobucket.com/albums/aa381/stephaneb74/34189253.jpg?t=1307993953

I know the long bars are messed up and I will probably redo them.... now that I have my idea on what I want ;)

http://i1195.photobucket.com/albums/aa381/stephaneb74/82772e18.jpg?t=1307993951


It was way too hot to be doing this lol so i had some beer... first beer in ages... I guess it is good summer comes back

http://i1195.photobucket.com/albums/aa381/stephaneb74/76d16865.jpg?t=1307993953


I am by no mean proud of the finished product lol but I am entertained with the process and somewhat amazed that I actually try to do it ;)


to be continued....

Mudderoy
06-13-2011, 03:53 PM
That shovel, although much more practical that one of those fancy small shovels, looks kind of scary. I think "Zombie Disposal Unit" would fit for this build. ;)

steph74
06-13-2011, 03:56 PM
ahah yeah and if it doesn't kill you instantly, you will die in sufferance from tetanos or splinters...

The idea of the crap on top was just to give an idea of the size lol... the shovel is not even fixed, it just rest on the side bars lol

4x4Dalton
06-13-2011, 04:13 PM
Hey not bad for yer first time fabbin one steph. Trust me I walked around mine numerous times makin sure this was straight that was lined up. If ya have any questions bro just ask.

4.3LXJ
06-13-2011, 04:16 PM
Hey Steph, this is how you learn. Jump in with both feet.

jccatt
06-13-2011, 04:24 PM
Gota start somewhere. Remember you made it, and it works.:-)

alwaysxj
06-13-2011, 10:48 PM
looking good steph, now we need to get that thing up in the mountains.

steph74
06-17-2011, 12:03 PM
looking good steph, now we need to get that thing up in the mountains.

I am working on it ;).... still have some bugs but that are bothering me but overall it is a much better vehicle than when I got it lol

cantab27
06-17-2011, 02:40 PM
nice work steph.......

steph74
06-17-2011, 02:47 PM
thanks guys....
well I am taking it appart.... the reason ? it was fun playing, but that thing on top has to be reliable ;) and safe...
So 1... I am redoing the base
2...I am redoing the lateral support bracket integrating suggestions from fellow site members ;)
3... I am replacing most of the self tapping screws with bolts to make it stronger (in my mind bolts are stronger and I don;t care if it is not true lol don;t destroy my dreams...)
and actually cheaper than self tapping screws...

alwaysxj
06-19-2011, 01:05 PM
let me know if you need any help glad to lend a hand, or if you are lucky two hands.

4.3LXJ
06-19-2011, 01:24 PM
thanks guys....
well I am taking it appart.... the reason ? it was fun playing, but that thing on top has to be reliable ;) and safe...
So 1... I am redoing the base
2...I am redoing the lateral support bracket integrating suggestions from fellow site members ;)
3... I am replacing most of the self tapping screws with bolts to make it stronger (in my mind bolts are stronger and I don;t care if it is not true lol don;t destroy my dreams...)
and actually cheaper than self tapping screws...

I am kind of the same way, I do it once and figure out how to make it better and then do it again.

steph74
08-20-2011, 11:05 AM
Time to update a bit.... things are going slow because I am seriously limited by time, money and weather 9in no particular order)

So recently I have finished the roof rack close to my liking. I have to tweak it a little and use some good old bolts instead of screws because of the stupid rattling.

I purchased a shackle and spacer 2" lift kit from Fat Bob's garage in Ogden UT (I put their website there and I gave them a card from XJTalk.com and told them to come and advertise here... Tony you should contact them to remind them ;) )

https://lh4.googleusercontent.com/--gGub52qn7E/TkiGDx5Y6eI/AAAAAAAAG78/ytBhvaEs6Mg/h301/11%2B-%2B1

https://lh4.googleusercontent.com/-LctIKpjqVHg/TkiGUywonpI/AAAAAAAAG8I/BKsgFi-BEcY/11%252520-%2525201.jpg

I had a local shop in town put the rear shackles in for me.... I read so many horror stories about the bolt breaking and having to cut the box and weld that I figured I was better off having the car in a shop with people that can do it... it took the guys about 2 h but nothing broke.
Then I got a spring compressor from o'Reilley and put the spacers on the spring in front.

https://lh5.googleusercontent.com/-cO4BG8_aI-Y/Tkg0QnXuT7I/AAAAAAAAG7c/8is0eS-BYqs/s512/11%252520-%2525201.jpg

Now she sits level and supposedly at 2 inches taller.... using the measurements posted on here though it looks like I have only 3.5 inches of lift total.... I don;t get it because i had a bastard pack and I am pretty sure the jeep was already 3 inches lifted...
I will have to scratch my head on that later....

anyway I am still looking to put bigger tires ghat I have... they are barely legal and one is really bad but the idea was to try them on, see if they clear and then decide to purchase better ones.. I had this set of 33's for $100 and 2 are OK ... nobody on town wants to do it... and they charge way too much for just a test... oh well we will see about that too...

https://lh4.googleusercontent.com/-UChnse0-5Uc/TkiGyCeD9XI/AAAAAAAAG8g/VIvcDx27fvs/h301/11%2B-%2B1

Then I put some lights on a roof bar, on the bumper and wired 2 on the back of the roof rack....
All circuits are 55W connected to a additional fuse box added to the engine bay...
it is not the super expensive 100W ones and I don;t care they look cool and they light up good enough to see.... and I do not have to upgrade my alternator or battery lol

https://lh6.googleusercontent.com/-PLNspZe-Ku8/Tk8qitD8l0I/AAAAAAAAG9s/SCOLUxR9PBQ/h301/11%2B-%2B1

https://lh6.googleusercontent.com/-Qgrxwcq_Bm0/Tk8qihHqhII/AAAAAAAAG9w/zfXOf4wDkm0/s640/11%2B-%2B2

https://lh3.googleusercontent.com/-m2t5IKN1juU/Tk8qi3zANWI/AAAAAAAAG90/JiVgf9R1Z8U/s640/11%2B-%2B3

cantab27
08-20-2011, 02:08 PM
shot steph...

steph74
08-20-2011, 02:52 PM
Oh I was going to edit my post with added pictures but I can;t see the edit button never mind

here are some daytime shots

https://lh6.googleusercontent.com/-EKIs387i8Mk/TlAOPkbbiwI/AAAAAAAAG_U/8OG3aXY1PYw/h301/11%2B-%2B1

https://lh5.googleusercontent.com/-UnzAQ-TNPH0/TlAOIx_9tLI/AAAAAAAAG_I/OSqkESphR_c/h301/11%2B-%2B1

https://lh6.googleusercontent.com/-Ihuu2PupxS8/TlANkEC1lfI/AAAAAAAAG-M/R7Oyq3kBHN8/h301/11%2B-%2B1

https://lh6.googleusercontent.com/-4kkQ6leIHd4/TlANtt-zPQI/AAAAAAAAG-Y/k-MFo_yBCe8/h301/11%2B-%2B1

https://lh6.googleusercontent.com/-ueZcXoBFIGA/TlANyjAzb5I/AAAAAAAAG-k/LUe9OsEI5ws/h301/11%2B-%2B1

https://lh4.googleusercontent.com/-ZJQaKhiObXU/TlAN2fFO7HI/AAAAAAAAG-w/m19hjg8MWN8/h301/11%2B-%2B1

https://lh5.googleusercontent.com/-EhUSflFhH1o/TlAOCRuD5CI/AAAAAAAAG-8/5MR9q6qimgU/h301/11%2B-%2B1

https://lh3.googleusercontent.com/-Ic76knFbijU/TlAOXgbwQPI/AAAAAAAAG_g/u7LHL20A0Oc/h301/11%2B-%2B1

4.3LXJ
08-20-2011, 06:26 PM
Lots of fun, right Steph? Looking good and I see a play day in your future.

steph74
08-21-2011, 10:06 AM
yes yes.... I still have some little gremlins that are bothering me... but I am less and less scared of digging into the electrical stuff....

For example it looks like my radio is somewhere connected on the "dome light" fuse and something in that circuit is blowing the fuse a lot ;)

steph74
12-20-2011, 03:23 PM
OK I have evrything ready for the task. The bolt has been sprayer with WD40 and PB blaster or whatnot, banged with a hammer a couple of time just to show who is the master...
Breaker bar in, muscles sharp.....
yes it is time to remove the front bolt from my broken leaf pack.....

After a couple of hours of physical activity, with the rusty old bolt, and a couple of cheap socket broken, I lucked out and the bolt start spinning....
Now so does the bushing sleeve.... nothing that a good vise grip could solve...

https://lh6.googleusercontent.com/-xJoh-3vRls4/TvAI3-DCerI/AAAAAAAAICY/ZB2_sR5zm90/s1152/IMG_20111219_210233.jpg

I got it out.... and I am hoping the other side goes that good ....

Yep it was broken all right...

https://lh5.googleusercontent.com/-Nf7xHspjUsY/TvAMfJeEVSI/AAAAAAAAIC0/uCca2JqlsBA/s1152/IMG_20111219_211800.jpg

steph74
12-20-2011, 03:25 PM
but I also played with the rear door... adding an accessorie that might be useful if I find a way to make it stop moving.....

https://lh4.googleusercontent.com/-z4Rzp3FVNLc/TvAJIFObYgI/AAAAAAAAICo/J0f9Wy2uFmY/s1152/IMG_20111219_210340.jpg

4.3LXJ
12-20-2011, 03:26 PM
Hey Steph, good to hear from you again. Rusty bolts are a pain on the XJs. So what is the end result you are headed for?

steph74
12-20-2011, 03:29 PM
Yeah I have been busy...

Well I bought a replacement pack from a local guy.... so I am replacing the whole thing.... I am not sure if I am going to just swap the top leave with he non broken one or mix and match differently...

I guess I will just have to play more....

4.3LXJ
12-20-2011, 03:36 PM
If I could offer a suggestion Steph, don't cut your center bolt off until you are done mixing and matching. That way you can do that without removing the main leaf. It goes much faster that way.

steph74
12-20-2011, 03:41 PM
I am not sure I understand... I have to remove the main leaf anyway right ?
(and yes suggestions are always welcome)

4.3LXJ
12-20-2011, 03:49 PM
Actually, you don't if you are intending to use a bastard pack, you know mixing and matching. I have done several variations on mine with leaves and with an impact wrench and floor jack I can so it in about 40 minutes because I have longer U bolts and leave the long center bolt uncut. So I just jack it up, remove the tires, remove the nuts on the U bolts, remove the nut on the center bolt and all the leaves fall free. Then I reverse the process to reassemble. You will find that if you are mixing and matching you will want to experiment to make it better if possible.

LizardRunner
12-20-2011, 04:00 PM
Here's a trick from the hotrodding world for making leaf springs work smoothly. I cut pieces of 6mil poly and place one inbetween each leaf of the spring pack. This allows the leaves to slide instead of grind against each other as they flex. The way I do it is to just trace the outline of the leaf on the poly with a sharpie then cut. When they are installed, they don't slip around, because the center bolt and the keepers are holding everything in place, but the ride is smoother.

steph74
12-21-2011, 09:01 AM
Actually, you don't if you are intending to use a bastard pack, you know mixing and matching. I have done several variations on mine with leaves and with an impact wrench and floor jack I can so it in about 40 minutes because I have longer U bolts and leave the long center bolt uncut. So I just jack it up, remove the tires, remove the nuts on the U bolts, remove the nut on the center bolt and all the leaves fall free. Then I reverse the process to reassemble. You will find that if you are mixing and matching you will want to experiment to make it better if possible.

That is pretty much the way I have done mine before.... yes I only had to cut the center bolt the first time because it was all rusty and seized... then I put a bigger one to match the donnor pack.....
following games were as easy as you describe. Only I have no impact wrench or powertools so it takes a little longer than 40 minutes lol.... but it is a pleasant, somewhat relaxing game when everything goes as planned.... ;)

4.3LXJ
12-21-2011, 10:38 AM
You're right, it is pleasant. It is nice to be able to change your suspension characteristics in such a short time. It is like having a "zipper" on it

steph74
01-02-2012, 11:57 AM
OK second side got finished...
Was not as easy and I have learned a lot.... I got frustrated a lot too....

This time I got the welded nut break and the whole bolt frozen int he sleeve spinning like crazy... After thinking about it and trying different approaches, I went all berserk with the angle grinder and first cut the main leaf off to make room, then cut the different layers of the main eye through metal and rubber bushing, then cut the bolt and sleeve in half, to realize that it was dumb...

cut a hole in the frame to get the stupid bit of bolt with the rust welded nut on it...

did several stores to fin a new bolt and nut (M14-120 if you were wondering).... got the 10.6 hardened one....

Held the nut through the frame with long hemostats while holding the leaf pack with my shoulders and trying to screw it in....

got everything bolted back....

and..... stupid bastard pack is not level and I have about 1/2 inch difference between left and right ;)

So back to the study board trying to figure out what to do next lol....

But I had fun and nothing beats the powerful feeling of cutting through your vehicle with an angle grinder and not caring much about the body.....

4.3LXJ
01-02-2012, 12:00 PM
Hemostats? You swipe those from the lab?

On another note, how did you make that bastard pack and what did you use?

steph74
01-02-2012, 12:07 PM
I actually bought them at a military surplus store... they are very long fine locking pliers with scissors tyoe handles..... much easier for me to handle in tight spaces

Well I think the pack is mostly stock leafs with a thick blade as second (I think S10 or most likely cheap AAL) I bought the pack used as is to replace that broken leaf I had... and 1/2" block.

Good new is when I change again, I will have no seized bolts....

4.3LXJ
01-02-2012, 12:15 PM
When you go to do that, you shouldn't have to remove the main leaf. Leave it in. It is much easier that way. Just get a new longer center pin (bolt). It is also much faster. Are you going for lift or stock height?

steph74
01-02-2012, 12:20 PM
Oh yeah I already have a longer center bolt..... I am looking at something like 3" max just like I had ....
And yeah I have played with them leaves before lol....

4.3LXJ
01-02-2012, 12:24 PM
Might I suggest using the bottom three leaves from the heavy duty S10 pack. It will have a keeper you can use and everything. Gives about 3.5" and doable with stock u bolts.

steph74
01-02-2012, 12:30 PM
yep this is most likely what I will end up doing.

my only pb with that was it felt very stiff to me... but sinc eit is not a daily driver, I can take all my time to play ;)

question> On the pack I got, the bottom leaf was very thick and flat.... basically a flat bar of steel
should I leave it ? Does it bring stiffness ? I had it first then removed it and it felt a little more soft...

4.3LXJ
01-02-2012, 12:56 PM
That depends on the construction of the spring. The leaf spring, no matter how it is made, needs a smooth progression of stiffness from no load to load. That is accomplished in two ways. A single stage spring has leaves of various lengths and the same thickness with the lengths evenly spaced from short on the bottom to long on top. A two stage spring has the longer leaves the same but the ones in the center are replaced by a long somewhat flat leaf, generally tapered to mimic several progressive length lower leaves. The two stage spring is used to increase load carrying capacity without sacrificing ride quality when unloaded. So that is why it called a two or multistage spring. It has a rate unloaded that increases a lot when loaded. In terms of flex, the single stage spring flexes the best since the spring rate is uniform.

steph74
02-06-2012, 11:27 AM
So I am broke, I am overwhelmed with work, I am moving .... but I managed to do a little something to the jeep ;)

I put the hitch back ;) I had removed it some time ago to rust protect it, and always been lazy... then I go tthese shackles and the bolts were sticking in the way.... when I played with springs last time, I inverted the bolts and this week end finaly got time to put it back.... I feel good because now I have a point for towing (or being towed most likely haha)

Then I cut the old tired fender flares, painted with a left over of truck bed spray paint, and screwed them on my folded rear fender.... it definitely looks like a redneck fix but matches the rest of the jeep so far...

now I am on the hunt for cheap extended LCA maybe, and possibly a front coil to level the whole thing.... thinking seriously to find a F150 one from the JY

Will keep updated of course but I am not expecting huge changes as there are chances that I will sell the jeep when it is my turn to move join my family :(

4.3LXJ
02-06-2012, 02:44 PM
Going to Portland Steph?

steph74
02-06-2012, 02:54 PM
Karen and the kids are.... I have commitments here until June at least.... leaves me more time to find a job and sell our house here.... we are moving Sunday lol...

LizardRunner
02-06-2012, 03:20 PM
Ahhh, well Steph, seems like Congrats are in order. BTW you will love the Portland Or. Area. good hunting and fishing all over the place there as well as wind surfing the three gorges area. and you need to keep the jeep, lots of wheeling opportunities you are going to.

4.3LXJ
02-06-2012, 05:00 PM
Steph, when you get settled, I will look you up when we visit the area. I used to live just south of there. Portland has lots of ethnic restaurants. I expect an education on good French cheese when I visit.

steph74
02-06-2012, 05:04 PM
Ah when I get there you will definitely be welcome to visit... I expect to go there during the summer

4.3LXJ
02-06-2012, 09:30 PM
Summer is great there. Always green. I mean, really green. Makes the rest of the country look drab. Be sure to go to the coast. The beaches are nice and the terrain goes from basalt rock to nice sandy beaches. Short Sands beach is the nicest I think. You have to hike through Old Growth forest to get to it. It is incredible.

steph74
02-07-2012, 09:47 AM
yes there are many things I am looking forward in this move.... I am more of a mountain person, but I hear from some French people that the coast of Oregon looks a lot like the coast of Brittany in France that I absolutely love (same wet climate as well...)

4.3LXJ
02-07-2012, 10:18 AM
You will also notice many French sounding names in the Portland area. The first Whites in the area to settle it were French trappers. The coastal area is actually a temperate rain forest. I love the woods there. Rule of thumb. If it is raining in Portland, it is probably nice at the coast. Water is cold though