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Last weekend I picked up a new project jeep. 2-door, XJ.
It is going to need a lot of work to get up and going. I have a good idea on what I want as a finished project.
But, I’m not really sure where to start. This will be my first build from the ground up and almost everything will be a learning experience.
Drive train will come out of a 91 Chevy 1500 z71. Except for the TBI. Ill figure that out later.

My thinking is to remove everything I can and clean, clean, clean. Fix any rust I might find and a good coat of paint.
From their start on axles. For the front I have a D44 limited slip out of a 89 bronco. Also a GM 10 bolt that is in rear of the donor truck.

So for now I am reading and learning. Gathering parts and ideas. Once i up my post count i will add some pictures. The jeep is sitting on a trailer. Full of random parts. Only thing still attached is the front links and axle housing.

Please let me know if you have any suggestions or ideas. This is going to be a dedicated trail rig. Trailered most places. Max of 35’s until I get 60’s. I am more of a find the right line and only gun it when needed type of driver. But I live in the south, so that can be a whole trail if its been raining.

Thanks in Advance
~Leaky
 

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I hate to be that guy but just buy some SD's. Weld them. Gear em if ya got the funds.

Leave em full width. Buy the biggest tire you can afford. Buy whatever stock wheel you can afford.

Buy a winch, make sure to plate the "frame" and the front and rear recovery points.
 

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Discussion Starter #3
Thanks for the reply.

I am going to get the jeep sitting on the axles I have and whatever tires I can trade for. That way I can roll it around and free up my trailer.
Your right, I should be reinforcing the frame and tow points while it is dissembled.
Any other suggestions to do while I have it completely apart?

I think a star is in my future. Speed up searching and post pics. Sounds smart to me.

Thanks
~Leaky
 

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You didn't say your location....hence, we don't know what shape the frame is in.

Considering the swap you want to do....a few pointers...and...as an FYI....I have the engine and tranny from a 93 Chevy PU in my CJ. The 91 is going to be almost identical

91 Means you have the 700R....which makes engine choices easier. My 93 has the 4L60E....which make it integrated in with the engine electronics. Not sure why you want to get rid of the TBI....pretty tough engines...and reliable. If you are changing it, I wouldn't do anything less than a Gen III TPI like the Vortec. But you will most likely need a wiring harness and compute that does not integrate with the tranny.

60's on a D44? Really? If you really think you want to go 60's....don't even think about using that D44.....You could regear it for 60's, but why waste the money? Do you realize what gears you need with 60's? Do you realize how much sheet metal you will need to cut off to fit 60's?

You need to check the width on those axles....if both are the same, well, no need to cut them down.

" I am more of a find the right line and only gun it when needed type of driver."...that is how you break shit and end up stranded on the trail.

The XJ is unibody....it's going to be a pain setting the engine and tranny....plan on pulling the fenders for easier access.

What year is the XJ? If new enough, it will already have the high pressure fuel pump to support a good FI engine.

If you are planning on putting in an engine with a carb? Then you are taking about 10 steps back. I personally will never run a carb'd jeep on the trails again.
 

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Max of 35’s until I get 60’s.
60's on a D44? Really? If you really think you want to go 60's....don't even think about using that D44.....You could regear it for 60's, but why waste the money? Do you realize what gears you need with 60's? Do you realize how much sheet metal you will need to cut off to fit 60's?
:homer: Come on @DDawg16 the man clearly says 35's until he upgrades to Dana 60's :flipoff2:
 

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:homer: Come on @DDawg16 the man clearly says 35's until he upgrades to Dana 60's :flipoff2:
I saw that.....but, to build something running on 35's with the intent to go to 60's? What he has for 35's won't work for 60's. Might as well start over.
 

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Discussion Starter #7
Thanks for the replies.

Forget all about tire size and axles at this point. ( 60's as in axles not tires) seriously why have 60" tires on a trail rig? where would the fun in that be?



I have a shell of a jeep, stuff full of all kinds of shit sitting on my trailer.
The only thing i am worrying about now is getting the jeep off of said trailer.
So far i have found all kinds of bits and pieces. decided to take pictures cataloging each item before storing it.

Hopefully we will do a little trail riding this weekend and i can get back to cleaning next week.

I like the idea of bracing all pull points and getting everything painted while dissembled . What other areas should i look to re-enforce?

The Wife has found a nice DIY weld in cage. thinking i should go ahead and do that before worrying about other stuff. you know safety first.

~Leaky
 
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