Cherokee (XJ) Rebuild and More

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Keboh

Keboh

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I have a 1995 Cherokee.. Currently, it's basically bone stock and my daily driver. It runs great, but with 360k miles, it's time to do some work before I go on any crazy trips so that I am able to go out into the wilderness with confidence. I have a trip to Moab planned in June, hitting a shit load of 4x4 trails on the way through CO, so it all needs to be done before then.

Build Priorities:
Engine
Brakes
Suspension/steering
Armor
Misc cosmetics, cargo, electronics

Here are pictures of the Jeep as it sits, now:


 
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Keboh

Keboh

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Test fit of the Hankook MTs I got for a great deal and wheels. 31x10.50 on 15x8 steelies w/ 4.75" backspacing:





 
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Keboh

Keboh

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I got a spare engine with the Cherokee when I bought it with unknown origins, so I decided to go dick deep and do a full overhaul.

I just got the short block back from a local machine shop (Vee Village). Once I get a warm weekend I will start assembly, but right now I'm stoked to have the first major expense done so it is all downhill from here to get the long block together.

Vee Village bored it out .030", new pistons, 10/10'd the crank, installed a new cam and assembled the rotating ass'y. We magnafluxed the head and realized it was trash, so we got a new core and put new valves, springs, seals, etc. Super happy with their work and the customer service there!





 
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Keboh

Keboh

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Spent my weekend figuring out the accessories I plan on running (pretty basic set up, for now). I'm adding an additional aux 12v port for the passenger front seat, 300w inverter, and LED spotlights.

I plan on running the inverter and lights through relays to switches. The secondary aux 12v I am just going to run straight to a switch.. it's only to charge cellphones so it'll only have ~10watts running through it, very low power.

Based on my math, everything here is very safe and I'm going just a touch overkill on my circuits to ensure I don't overload anything. It also allows me to upgrade down the road or add additional accessories without having to rewire.

Here is my quick-and-dirty schematic:

 
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Keboh

Keboh

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Lol they're only 31x10.50s... they just look huge on stock suspension! As-is though, they're too big for the Jeep to move with them on. They would rub on all the things, lol.

Once the long block is together and I've bought all the motor stuff, I'm getting a super-flex 3.5" RE lift kit w/ Bilstein 5100s. I bought the tires around Xmas because there are always big tire sales around then and I found these for a bargain. I've ran the Dynapro ATm tires and loved them, but for this Jeep I wanted to go a little more aggressive so I grabbed a set of the MTs!
 
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Keboh

Keboh

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cdunn334 said:
It this a new fuse box?
Click to expand...
Yep! I put a new positive terminal on my battery so I could run another power wire directly off it for my accessories... I routed it back to that fuse box (picked it up off Amazon) on the firewall on the passenger side, which is what you see there. I'm going to bolt a couple relays just to the right of that for my inverter and lights. It's denoted in my schematic above.

More pictures to come showing the whole system routed, how I ran my wires, etc.
 
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C

cdunn334

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Keboh said:
Yep! I put a new positive terminal on my battery so I could run another power wire directly off it for my accessories... I routed it back to that fuse box (picked it up off Amazon) on the firewall on the passenger side, which is what you see there. I'm going to bolt a couple relays just to the right of that for my inverter and lights. It's denoted in my schematic above.

More pictures to come showing the whole system routed, how I ran my wires, etc.
Click to expand...
Yeah, In looked it up and bought one for my hoe. Thanks


Sent from my E6810 using OB Talk mobile app
 
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Keboh

Keboh

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cdunn334 said:
So far just going to be a couple small LEDs and a cb.

Sent from my E6810 using OB Talk mobile app
Click to expand...
LEDs, I would run through a relay. The wattage will determine how thick of gauge wire you need and what size fuse you ought to use.. check my diagram out above to wire your lights (like mine). My LEDs are only 40watts total, little spot lights. For a full bar, they can go up 150-200watts+ and will require thicker wire, depending on how long the wire run will be.

CB, I'm not certain what kind of power these require.
 
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Just Me

Just Me

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Traveler I

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SE Michigan
Have you thought about upgrading the intake to the newer 97' model? Excellent to see old XJ's being saved instead of put out for new stuff.
 
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