96 Jeep ZJ Build

[TxRanger3006]

My plans are for a good all around overland vehicle with custom camping amenities and the ability for long trips. Here’s where I’m at so far.

So I’ve had several but I’m hoping this is the last one so I can stop swapping parts around. I’m currently working on the motor between my last jeep and a few more parts that came in, I’ll be replacing everything except the block for the most part. The replacement highlights would have to be my new high flow headers that I’ll be wrapping, WJ intake mod with webbing trimmed out, injector upgrade, all aluminum radiator and some other goodies. I also have a long arm front and short rear lift all I need are my new Fox shocks and new coils to finish that. Additionally I have 2 full interiors that I’ll be going through to come up with a clean hopefully brand new look with updated carpet and headliner.

Body wise I will be doing the normal trimming of the fender wells, and additionally cut the old rocker panels and replace with 2x6 anchored to the unibody. Frame stiffeners and new under body coat will be added to keep it clean and beef it up. I also had a vented hood from a 5.9 project that I put on it to help air flow.

That’s about it I’m sure I left stuff out but I’ll add pics as I progress and would love helping any others with zj questions or if anyone’s searching for parts, I have had zjs for almost 15 yrs now and love em so I have different lists built for bolt/bulb sizes along with fluid amounts and types.

 

[TxRanger3006]

Also I forgot the basics

1996 4x4 with a 4.0 that has 214k miles

 

[adventure_is_necessary]

Also I forgot the basics

1996 4x4 with a 4.0 that has 214k miles

What tcase do you have in it?

 

[TxRanger3006]

It has a 242 stock but I had a 231 I’m rebuilding with new internals and bigger chain to swap in

 

[adventure_is_necessary]

It has a 242 stock but I had a 231 I’m rebuilding with new internals and bigger chain to swap in

Solid choice. I have a 242HD I am considering freshening up with an SYE kit to take place of the 247. I haven't decided since the 247 hasn't really given me any reason to swap. Look forward to seeing this build!

 

[TxRanger3006]

Thanks and I’m looking forward to finishing it to get on the trails, it’s been too long. I’m also not swapping mine over for a while either mainly due to money but also cuz mine is working fine too and I’m not doin any crawling yet so not in a rush.

 

[slomatt]

It's good to see more ZJs on here. I had a 96 V8 which I still miss.

 

[TxRanger3006]

It's good to see more ZJs on here. I had a 96 V8 which I still miss.

I’m kinda bummed I haven’t seen more on here, there a good platform, easy to work on and cheap to find.

 

[Smileyshaun]

I really do miss mine some days I love the way it Road and drove with the Rubicon Express superflex kit.bumps and gravel roads we're no issue you didn't even feel them the only thing I didn't like about the whole set-up was with the superflex kit having Hymes at both ends it transmitted a ton of road noise into the cab if I had to do it again I would go with the Super Ride kit as it was more of a daily driver weekend exploring vehicle then it was a rock crawler

 

[TxRanger3006]

I really do miss mine some days I love the way it Road and drove with the Rubicon Express superflex kit.bumps and gravel roads we're no issue you didn't even feel them the only thing I didn't like about the whole set-up was with the superflex kit having Hymes at both ends it transmitted a ton of road noise into the cab if I had to do it again I would go with the Super Ride kit as it was more of a daily driver weekend exploring vehicle then it was a rock crawlerView attachment 96137

Yea that’s a clean looking zj I’m def a fan of simple but capable when it comes to the grands. I have an iron rock critical path (long arm front) that I took off another zj I had but instead of the 7” I’m swapping the springs for 4.5 since I’m not really crawling in Florida. The Heim’s are only on the axle end for the long arms and reg bushing for the rear.

 

[TxRanger3006]

So I started tearing into the motor today got most of it apart and drained most fluids so tom I will finish taking it apart then finish the couple mods I have and put it all back together. At the end I’ll show a before and after pic of the engine bay.

Here’s the new (off my previous jeep) aluminum radiator


New condenser


Intake upgrade and webbing being cut, green is what’s done red is tomorrow


New headers that will hopefully be wrapped tomorrow

 

[TxRanger3006]

So progress got slowed down a bit as I wait for my intake, valve cover and fuel rail to come back from powder coating (last min change of plans) but I did get the motor cleaned up and repainted with por15 high temp.
Front before/After


Passenger side before/after



Driver side

 

[TxRanger3006]

Some more parts came in one ton over knuckle steering, front 4.5 coils, adjustable double shear trac bar, front/center frame stiffeners and hd coil retainers.

Slumberjack tarp with screens


And I picked up an oven/stove combo that I need to clean up but got it cheap

 

[Viking1204]

Looks good, can't wait to see it out on the trails!

 

[TxRanger3006]

Looks good, can't wait to see it out on the trails!

Me too

 

[TxRanger3006]

Got my powder coating back finally and did a mock up of what it will look like installed. Also got my header cerakoted instead of wrapping them. Now I finally think I have all the parts for the motor so I just have to finish installing.

 

[Viking1204]

Looking good!

 

[adventure_is_necessary]

Very clean. What are the perks of using cerakote on that application?

 

[TxRanger3006]

Very clean. What are the perks of using cerakote on that application?

I did it mainly to help reduce heat in the engine bay since the Grand Cherokee is known for running hotter. It also helps prevent corrosion from salt and what not on the outside and helps reduce corrosion inside the headers from heat, protects from road debris damage and is also chemical/oil resistant. The big plus is my header should stay black instead of fading or changing color from the heat it’s moving. Also after I finish building the exhaust piping I’ll coat it the same for the same benefits.

 

[TxRanger3006]

Got a little more done today, did the new distributor and waterproofed it, also had to redo my timing, finished painting anything I missed, got the valve cover/header/intake all mounted. Just gotta finish hooking everything up, then I’ll start the radiator support and steering brace.