What I have learned about the WJ so far: (no revelations but observations and confirming what others say...)
Ride is fantastic off road. I went from a 76 Cherokee to a Z71 Chevy Truck to a Tahoe to the WJ. The WJ is the most comfortable platform yet!
Flex is good stock, but disconnect front sway bar. The flex will increase even more dramatically, earn comments from the IFS guys, and reward you with a Cadillac ride off road. But, tire clearance amps to a whole new game when disconnected. A little rub when testing will be a major rub when in the rough. Bumpstop spacer length needs to be dailed in. To get the most out of the vehicle on road, after a lift definitely add the appropriate extended sway bar links and make sure geometry is in spec.
I really, really, really prefer the ride with the Rancho 5000x shocks over the Billsteins (which I thought were good). I can feel more with the Rancho, but it is not jarring or harsh, just better trail feedback so I know what is going on and less bottoming on the bumpstops. Doing 45 mph over washboard in Saline Valley made for a pleasant drive (but it killed the Billstein shocks). Install front bumpstop spacers, real ones, not the cheap boxed ones, when you install an upgraded track bar. Keep the bar off of the oil pan at full compression! Also, a 2x4 can be used as a replacement bumpstop spacer if you crush said cheap thin Amazon spacers doing 45 mph and hit an erosion ditch in the road.
Packing the WJ is a challenge, the cargo room and load capacity is limited. I had to get a backpacking mindset back. I do not feel much difference in handling with cargo on the roof (the Tahoe would sway noticeably). But mpg suffers. Coming home from the last trip, with gas cans on the roof and fighting the wind on highways 99 and 152, I was down 1 1/2 mpg. The cargo weight (max vehicle weight) of the WJ is limiting. Me and my co-pilot are big people, so we use up a bit of weight capacity. I took the electric seat frames out and installed manual, saving 20 pounds each. This allows me to carry my tool kit and a bit of recovery gear without going into the weight budget. With the rear seat bottoms removed, I lay out the soft toolbags across the floorboard and strap them in. Access is good and the weight is very low and centered in the vehicle. The axe and shovel fit under the folded down back seat top. With just a cooler and the tools/recovery gear, the ride is very neutral and the WJ ride is incredibly smooth. But a 7 day trip to Death Valley, with full load out and 2 people, put us just above max. With just me, I could do a 14 day trip and stay well below max weight.....
The hydraulic cooling fan makes me nervous. Temp bounces between 195 and 215+ seemingly at random. Strangely, temp drops if I run high range on long uphill grades and keep the RPMs down. I believe it is because the transmission temp increases enough to kick the fan into gear. With the 4.7, overtemp is a killer, so I would like some control of the cooling system. Underhood temps are always much higher then I like, the fan at idle does not push any airflow through the engine bay. The later model 3 wire solenoid is not adjustable so I have to live with the low fan idle rpm. I believe any constant airflow will help maintain a steady 195, and be that much easier on underhood components. For that reason a conversion to the 99-2000 electric/mechanical fan system is in the works. I will run the mechanical as primary and the electric fan to kick in at 200 degrees. I want the piece of mind I will not overheat this engine.
Why 3 1/2 inch lift? I chose this used WJ specifically for how it was optioned. It has full skids (i wanted the gas tank skid), Cardan joints (no Repezza), 242 transfer case, and Dana 44, V8 for me and a sunroof for the copilot. It will handle just below 4" lift withough needing to drop the transfer case, replace drivelines, install a slip yoke eliminator kit, and the like. At 4 inches things become marginal, and to do it right the expense goes way up. To the point where you might as well go 6". I am amazed at what I have done with the budget boost, and feel I will be able to do what I want without going extreme. 3 1/2 inch is the best value for the capability. And I will still be able to source many junk yard parts (like drivelines) if I need to get out of a jamb. Also, road manners will be fantastic. Going long arm in the front is just for luxury....and in case I want more later.
On this WJ, the two weakest points are the radiator and Dana 44HD aluminum housing. I will be adding a Goliath front skid to protect the radiator. The factory plastic bumper offers no protection. Any slip against a rock, a hit a stump while driving through grass or snow, it gets backed into, etc. will pop the radiator. A little steel in front will help that. The aluminum housing on the D44HD cannot be jacked up from the pumpkin, or it can deform and screw the ring and pinion setup. Same goes if you smack one of the axle tubes. Otherwise it is more than formidable for the platform. So in will go a truss and skid plate modified differential.
Lastly the gas tanks hang low. Even with just the budget boost, the only thing I have smacked on the trail is the gas tank when coming down a granite step. So a tank tuck is planned in the future.
