NAXJA Forums -::- North American XJ Association  

Go Back   NAXJA Forums -::- North American XJ Association > NAXJA Unibody Jeep Technical Forums > Jeep Cherokee XJ (1984 - 2001) > Modified Tech Discussion
HOME Member FAQ Sponsor Info Rules Bylaws E-Mail

Modified Tech Discussion Forum for Tech related discussion for Modified XJ's and MJ's.

Reply
 
Thread Tools Display Modes
  #1  
Old July 11th, 2012, 18:09
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
WJ knuckle swap and 1-ton steering complete

I benefited over the past several months by gathering information from different post to do my WJ knuckle swap and 1-ton steering upgrade.
Thought I'd post up pictures and parts I used this weekend to finally get it all installed.

Pieces and parts:

U-pick it:
01' WJ knuckles, and Calipers, PS pump
98' Durango box

New parts:
01' XJ upper ball joints
01' WJ lower ball joints
01' XJ unit bearings (mines an 01' already but I figured I'd replace while in there)
JKS Flange spacer
02' Explorer Sportrac rotors ( important b/c 01' wont fit, I tried)
New brake pads

1-ton steering:
I went with 1.5" x .25 wall DOM. Some may say overboard. But now I dont need a front skid this stuff is beefy.

Ruff Stuff Specialties
Fast shipping and great prices. DOM was cheaper shipped than I could buy it local. They have just lowered their shipping, its $17 flat for steering components with DOM. Cheap considering the almost 60 lb shipping weight.

They have Steering Component Packages They are generic but can be put together for what you need.
I used one ton GM crossover steering set but used offset TRE's for the stabilizer. I used a mis-alignment TRE for the pitman arm side of the draglink. This gives alot more droop to the passenger side instead of being held up by the draglink.

Off center trackbar axle bracket
3/4" heims
and same DOM for trackbar setup

I wanted to use heims so I didn't use the JKS over the axle bracket

Don't forget
Jam Nuts
TRE inserts
And anti-seize!
Now a series of photos of the process....

Last edited by Dustys; July 11th, 2012 at 18:14.
Reply With Quote
  #2  
Old July 11th, 2012, 18:31
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

DOM and TRE from Rough Stuff
I beginning to doubt that I need this ridiculous size. This is what happens when friends send you emails of stuff you ought to buy...

Untitled by Agustus McCrae, on Flickr



Weld on JKS flange spacer to the passenger side knuckle


Sandblasted the knuckle clean. Some have thought it not necessary to weld on the flange, I disagree as does JKS. Disclaimer: I am not a professional welder, I am a hobbyist, I consider my sources and use advice from others to form best practices.
That being said, Important to get the knuckle hot with a torch for it to weld properly, then do it in stages and stick it in a bucket of sand to cool, so the welds don't pop from cooling to fast.

TIG was a little hard to get in there. Had a 1/4" deep channel between flange and knuckle to get first few welds into.
Reply With Quote
  #3  
Old July 11th, 2012, 18:50
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

Weld on one side of the inserts to the DOM the others after the knuckles are installed and measurements are taken.



Ream the knuckles


Everything is working fine, the taper went smooth the TRE fits snugly Right? WRONG. This is supposed to be an OVER the knuckle steering so tapering the holes in the stock direction got me nowhere. I only did one backwards, but to late I might as well have done them all that way. So plan B, I just drilled them all out 7/8" and welded in tapered inserts. I had a buddy to the 7/8" drilling at his shop with a industrial drill press. the taper self centers so I could do that at home, but a straight bore has to be angled in more than one direction so a drill press that moves is preferred.
Reply With Quote
  #4  
Old July 11th, 2012, 19:01
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

Paint em' up!

I like this stuff, time will tell how trail proof it is. But it goes on well with a brush and thats always a plus.


Reply With Quote
  #5  
Old July 11th, 2012, 19:21
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

Old and new brake and rotor comparison. Along with a shop tool for size comparison.



This is the incorrect rotor, same size but out of an 01' instead of an 02' sportrac. The hub isn't deep enough.



Install






Axle Trackbar mount. Its clocked forward about 10* to clear the upper control. Stock bracket and stabilizer bracket was removed.


Reply With Quote
  #6  
Old July 11th, 2012, 19:51
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

There are some clearance issues to be aware of....
Better make sure your wheels are large enough, stock wheels you can forget about.. I have 15" Mickey Thompson's with a good bit of offset, and they don't taper on the inside but it was close.


This picture is misleading. Its not touching anywhere and there is a fair amount of space at least an 1/4" all the way around the caliper. But still tight.



The offset TRE contacted the wheel on full lock turns. Granted you won't be doing full lock at any speed but still no good. I ground the edge of the TRE since there seemed to be a little extra cast there where it was rubbing and have maintained good clearance there since.




Some have mentioned spacing issues with the sportrac rotors and the calipers. My calipers rubbed the back side of my new rotors and gouged them pretty good. I had to add 1/16 inch thick washers behind my calipers to get the proper spacing. 1/8" spacing would be about perfect and I have a disc rotor spacer on order to correct that since washers are dangerous in that position.

I don't know if it was the O'rilleys house brand rotors or the NAPA unit bearings but the back of the rotor was .010 too small to slide over the hub flange. So, started it up, put it D, and lightly held a spinning flap disc to the the top of the flange and presto.

Hope some of this helps.

Feel free to ask ???

Last edited by Dustys; July 11th, 2012 at 19:57.
Reply With Quote
  #7  
Old July 11th, 2012, 20:01
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

Take it out for a flex. Gained a lot of drop on the passenger side now that my stock draglink isn't hanging the axle up. Now its just the brake lines... tight as banjo strings. Looks like its time for longer ones again. Sorry, it was a little dark out.

Reply With Quote
  #8  
Old July 11th, 2012, 20:08
jbsjunk's Avatar
jbsjunk jbsjunk is offline
NAXJA Forum User
 
Join Date: Jun 2009
Location: West Mich
Posts: 312
Re: WJ knuckle swap and 1-ton steering complete

Subscribed. I dig this.
Reply With Quote
  #9  
Old July 11th, 2012, 20:33
philagony94xj's Avatar
philagony94xj philagony94xj is offline
NAXJA Forum User
 
Join Date: May 2007
Location: Schererville, Indiana
Posts: 979
Re: WJ knuckle swap and 1-ton steering complete

Kudos sir!

Good job with the pics of the process. I think this will help clear up ALOT of questions that creep up everytime a thread with a WJ knuckle swap is brought back from months ago.
Reply With Quote
  #10  
Old July 11th, 2012, 20:47
Dustys Dustys is offline
NAXJA Forum User
 
Join Date: Feb 2012
Location: Kansas
Posts: 37
Re: WJ knuckle swap and 1-ton steering complete

Thanks! I found the lack of photos a little frustrating too. There is a lot of good information out there but it is spread around a bit. I wish I had time to be a little more thorough with part numbers and step by step assembly.
Reply With Quote
  #11  
Old July 12th, 2012, 16:46
jdbwrx jdbwrx is offline
NAXJA Forum User
 
Join Date: Jan 2005
Location: Avon, CO
Posts: 675
Re: WJ knuckle swap and 1-ton steering complete

Nicely done and a good write up!

The hammered Rustoleum holds up pretty well. It's easy to touch up too.
Reply With Quote
  #12  
Old July 13th, 2012, 04:00
VAhasnoWAVES VAhasnoWAVES is offline
NAXJA Forum User
 
Join Date: Sep 2008
Location: Lake City, Mi
Posts: 5,397
Re: WJ knuckle swap and 1-ton steering complete

if i did the WJ swap, this is EXACTLY how i would do it. great work.

what diff cover are you running and how much clearance is there?

the offset TREs dont look like they would be a problem with moabs. good to know.
Reply With Quote
  #13  
Old July 13th, 2012, 05:32
sunburned sunburned is offline
NAXJA Forum User
 
Join Date: Jan 2008
Location: So. MD
Posts: 1,995
Re: WJ knuckle swap and 1-ton steering complete

Wish I had done this. Also wish Jeep had put those knuckles and brakes on the XJ to begin with...
Reply With Quote
  #14  
Old July 13th, 2012, 06:02
Lowrange2's Avatar
Lowrange2 Lowrange2 is offline
Member# 2368
 
Join Date: Nov 2006
Location: Abbeville, SC
Posts: 15,711
Re: WJ knuckle swap and 1-ton steering complete

Looks good, man.

Mine looked Juuust like that. kinda. lol Mine wasn't painted up quite as nice. I used the JKS TB Bracket and TRE's all the way around.
Reply With Quote
  #15  
Old July 13th, 2012, 07:50
troy5118 troy5118 is offline
NAXJA Forum User
 
Join Date: Apr 2011
Location: Ks
Posts: 116
Re: WJ knuckle swap and 1-ton steering complete

You're a pretty smart guy huh?!
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
WJ knuckle swap JKS steering question truck7575 Modified Tech Discussion 12 June 12th, 2011 22:34
WJ brake/knuckle/steering swap to a ZJ peej08 Modified Tech Discussion 11 April 26th, 2011 21:00
quick WJ knuckle/brakes/steering swap question about TRE's huntingman2706217 Modified Tech Discussion 9 March 11th, 2010 07:47
Steering stabalizer on WJ knuckle swap...? 89xjgrey Modified Tech Discussion 15 May 15th, 2009 15:06
Complete HP D30,ARB,With over the knuckle hiem steering David Taylor For Sale: Private Party Only. XJ ITEMS ONLY 3 November 10th, 2003 21:52


All times are GMT -7. The time now is 23:22.


Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
NAXJA and NAXJA logo's Copyright NAXJA. All content/images Copyright NAXJA 1999-2014