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Fraz's Budget Build - '96 XJ Cherokee Sport 
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Post Fraz's Budget Build - '96 XJ Cherokee Sport
After getting some work done to the XJ today, I figured it was time I started documenting this build up.

A lot of the younger guys at work have started picking up old solid-axle vehicles for VERY cheap. Before I bought the XJ, there was an '88 GQ Patrol with 400K+ on the clock, an '84 60 series cruiser getting rebuilt, an '86 leaf/leaf hilux and an old MQ Shorty patrol. Everyone kept pestering me to get something oldschool that I could go to town on, but do so without breaking the bank.

After talking to a number of overseas and local distributors, I settled on an XJ Cherokee. The main reason was the 5-link front end, which offers heaps more flex from standard than any of the above vehicles. I just had to find the right one at the right price.

Anyway, a very clean '96 Sport came up on Gumtree for $1400 with auto issues. I haggled the seller down to $900 without rego, and the deal was done. Picked the car up the next night and towed it home. Put 6 months rego on it the day after that and she was good to go. Having driven it around for the past couple of weeks, there are a couple of issues I'd noticed:
-Wouldn't start when hot, and will randomly stall when changing gears after driving around town;
-Had to change gears manually, meaning a loss of 2nd gear.
These have since been rectified, which I'll cover later.

The whole point of this build is to create the most capable off-roader for under $10k. So far I've spent $2100 including rego, insurance, servicing and initial purchase, so I'm off to a fairly good start. I'll be building as much as I can myself for this (rear bar, sliders, etc.), although I'm pretty sure I've got the best start, that 5-link front flexes extremely well. 8)

Alright, first issue: Inconsistent starting habits.

After testing the injectors, fuel pump and relay, dizzy and everything else I could think of, it was left down to the Crank Angle Sensor. Sure enough, it was malfunctioning. New one was ordered through work and fitted today, and has done the trick. Starts up within the first couple of cranks now. :D

Next problem: The non-auto Auto.

I had to manually shift through the gears as the auto box would simply try and take off from a stand-still in 4th if left in D. This was alright for a while, but the TC wouldn't lock-up on the highway either, which was seriously killing the fuel economy. I know the XJ isn't great on fuel, but 15L/100km on the highway was a bit crap.

Anyway, after testing the NSS and checking all fuses and relays for the TCU, the only thing left was to pull it apart. Found a thread on AusJeepOffroad from a member with identical issues, and his fix was to replace the solenoids. Rather than just do the two shift units, I replaced all three (TCC, Shift 1, Shift 2) as I didn't want to have to pull the pan off again to replace another further down the track.

2.5hrs on the hoist, and it was all done. Had a little issue with the clearance between the pan, exhaust and crossmember, but got there in the end. Put a filter kit and new oil in at the same time as the original ones were completely cactus. The cork was hard and brittle, and the oil was dark brown. :-? New gear all fitted up with fresh new oil, and it was running like a dream. Oil level is a little above the full marker, but not enough to worry about.

I'll be doing a full service on the rest of the engine tomorrow, so will hopefully get her purring like a kitten again. 8) After that will be a full new stereo system, as I got a decent Pioneer head-unit from a few friends for my birthday. :D Just have to get the amp and speakers now.

Gratuitous Flex Shot with the boss' GQ Patrol:
Image

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Last edited by fraz91 on Sun Aug 25, 2013 11:53 pm, edited 1 time in total.



Sat Aug 24, 2013 7:55 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Sweet :D

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Sat Aug 24, 2013 10:29 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
You copy and pasted that didn't you?

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Sat Aug 24, 2013 10:58 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
^ I thought the same thing...

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Aut '94 FTO GX (Thrasher)
Man '92 Legacy GX (Daily)
Man '89 Legacy RS (Now a shell)
Man '89 Legacy RS Rally car (Being built)


Sun Aug 25, 2013 12:01 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Technikhaus wrote:
^ I thought the same thing...


fraz91 wrote:
I know these things aren't great on fuel, but 15L/100km on the highway was a bit crap.

fraz91 wrote:
Found a thread on here from a member with identical issues...


dead give away!

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Sun Aug 25, 2013 12:15 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Yeah yeah, I may or may not have posted the same thing to another forum and been lazy :lol:

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Sun Aug 25, 2013 12:54 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
haha, as we've noticed :p

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Aut '94 FTO GX (Thrasher)
Man '92 Legacy GX (Daily)
Man '89 Legacy RS (Now a shell)
Man '89 Legacy RS Rally car (Being built)


Sun Aug 25, 2013 1:19 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
What smiley is :cool: on the "other forum"?

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I just had to add it ......
sublime19 wrote:
Lol clearly you don't know me well enough, it was a joke :roll:
I talk a lot of sh*t, usually have to keep a roll of toilet paper handy in the car for my mouth :lol:
Astron_Boy wrote:
Hold me Sooty, I need man comfort.
:utbnb:


Sun Aug 25, 2013 8:59 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
rock_it wrote:
What smiley is :cool: on the "other forum"?


:utbnb:

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Sun Aug 25, 2013 9:50 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
SchumieFan wrote:
rock_it wrote:
What smiley is :cool: on the "other forum"?


:utbnb:


ROR!

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I just had to add it ......
sublime19 wrote:
Lol clearly you don't know me well enough, it was a joke :roll:
I talk a lot of sh*t, usually have to keep a roll of toilet paper handy in the car for my mouth :lol:
Astron_Boy wrote:
Hold me Sooty, I need man comfort.
:utbnb:


Sun Aug 25, 2013 10:11 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
So a few little things have happened to this beast so far.

The budget has been dropped to $8k, and I think I'll be well under that even with a few extra bits and pieces.

ANYWAY

Swapped the original steelies and cheese-cutters for a set of TJ Wrangler Alloys with 31" muddies. They're LOUD, but nothing a little radio can't fix ;) They also scrub just about everywhere, so I really need to get the lift fitted. :| Most of the parts have arrived, but I can't build the shocks until the front control arms and steering rods turn up. Need to get as much suspension travel as possible from this thing.

Before:
Image

After:
Image

edited so you numpties could view the photos of my fantastic turd :lol:

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Last edited by fraz91 on Fri Sep 06, 2013 5:11 pm, edited 1 time in total.



Fri Sep 06, 2013 11:18 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Images no work for me.

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Fri Sep 06, 2013 11:20 am
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Images don't work for me either :(

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Man '96 FTO GPX
Aut '94 FTO GX (Thrasher)
Man '92 Legacy GX (Daily)
Man '89 Legacy RS (Now a shell)
Man '89 Legacy RS Rally car (Being built)


Fri Sep 06, 2013 12:01 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Attachment:
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Daniel2019 wrote:
I found it easiest to start getting it off from there and then just run your hand down along the side and across the top.

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Fri Sep 06, 2013 1:06 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
All I see is

Image

And to that, I will show my:

Image

:lol:

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Fri Sep 06, 2013 1:54 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
That should hopefully have fixed the image issues you were all having. It turns out ausjeep doesn't allow the photos uploaded there to be used elsewhere. :lol:

Anyway, here's some new goodies that arrived today. Hope to get these installed tonight so I can drive it to work tomorrow. 8)

Image

Image

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Fri Sep 06, 2013 5:14 pm
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Joined: Sun May 27, 2007 5:00 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Yes, the car does need lift!

Your license plate is crooked.

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Fri Sep 06, 2013 5:31 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
Astron_Boy wrote:
Yes, the car does need lift!

Your license plate is crooked.


Yeah, I know. I have to "adjust" the standard licence plate holes to fit the heep's plate bolt pattern.

And now, one from the side:

Image

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Fri Sep 06, 2013 5:33 pm
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Posts: 881
Location: 4wding over you, Sydney
Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
It grew over the weekend.

Image

Once I get all the front control arms, I'll be able to lift the front another inch to level it out a bit. Will also pull the leaves out and de-camber them a bit, as I'll be putting in shackle relocation brackets for more flexibility. 8) Once that's all done, I'll build up a set of monotube shocks (gotta practice my TIG welding) and she'll be apples. :D

_________________
I'll have an FTO one day... i swear!

until then:
1. 2001 Merc-Benz A160 (porta-loo on wheels)
2. 2007 Peugeot 307 TDi (more fun than you'd expect)
3. 2009 Mitsubishi Triton Di-D (a monster in its own right)
4. 1992 Nissan NX Coupe (club car and project car)
5. 1996 Holden SB Barina - "The Nugget"
6. 1996 Jeep XJ Cherokee Sport - The Budget Build
7. 2010 Toyota Landcruiser 76 Series - V8 Goodness... - Build coming soon.
8. 1990 Audi 90 manual - The delightfully dignified daily driver
Astron_Boy wrote:
No correction needed Gen Y, you are correct.

Bennoz wrote:
My rubbing happens on the inside.


Mon Sep 09, 2013 12:20 pm
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Post Re: Fraz's Budget Build - '96 XJ Cherokee Sport
It is still a Jeep, but I concede, it's growing on me a little bit. (not a pun from height raise, you already did that one)

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Mon Sep 09, 2013 12:23 pm
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