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I had a vibration coming from my front driveshaft that ended up being the front output bearing of my transfer case. Even the smallest amount of play in the bearing indicates that it is bad.

High NOx is indicative of high combustion temperatures. How is your cooling system? Otherwise, unfortunately, a new catalytic converter might be the best solution. Because of your previous exhaust leak, running rich might have put too much strain on the cheapo amazon cat and caused it to fail...

Are you talking about ethanol-free gasoline? The studies I've read show fuel with a small blend of ethanol (10% is typically what is sold) actually results in lower levels of hydrocarbon and NOx emissions.

On the 8.25, backlash must be measured after the preload torque is set. What I saw, when setting up new gears, is a 0.004 to 0.006 increase in backlash between setting the left (driver) side and the right (passenger) side / preload. So it becomes an iterative process of 1. set the backlash using...

In theory, a crack in the exhaust manifold will tell the (upstream) O2 sensor that there is too much oxygen and it will richen up the fuel mixture. That might result in a higher hydrocarbon reading. So hopefully, replacing that header will help you out. I also use 85 octane but I'm not picky...

I second Anak, although on my 1997 the silicone was red/orange in color. In that case, there is no need for replacement. Just remove it.

I run the Tenneco stabilizer, 2 years with no problems. I bought a FOX stabilizer, which stated it was for XJs, on craigslist, but it did not have enough travel for me so I had to resell it.

Congrats on the junk yard find - that's a steal! I have Iron Rock Offroad steering. I run blue (medium strength) loctite, but the bolts are double-nutted: one standard and one nylock. I use blue on both nuts. 1. If the CavFab kit has double nuts, blue is sufficient. Otherwise, I'd tend to...

Sounds like the switch is leaking. Replacement with a used part is probably the easiest solution (ebay, junkyard, etc). You could try to find the leak by pressurizing it and spraying soapy water (or use a smoke machine if you have one), and then epoxying the leak, but that thing is small and...

Can you check to see that 86 is getting 12V and 85 is being grounded properly?

Looking through my 1997 service manual, I think the piece with two terminals is just a connector - nothing special. The terminals are called "field terminals" and one should be 12v constant, and the other one varies.

Do you have a multimeter? Can you measure the battery voltage directly?

I'm trying to find a good pattern on my Chrysler 8.25. Here are the specs: Ratio: 4.10 Depth shims: either 0.036, 0.038, or 0.040 Pinion preload: 20 in-lbs Carrier preload: 75 ft-lbs Backlash: 0.008 My shim pack only allows adjustments of 0.002. I think 0.036 looks too shallow and 0.040...

You could always go with South Bend or Luk, but they're a little more expensive. I think they switched to an external slave cylinder in 1994, so you won't have to drop the transmission to swap it. Should be a simple replacement. Napa's return/exchange/warranty policy is excellent though, so...

Got around to finishing this installation. The pinion preload needed two attempts, as for some reason my preload almost vanished after I put the seal in the first time. I measured 15 in-lbs, installed the seal, and all of a sudden measured 3 in-lbs. My theory was that I didn't oil the pinion...

Thanks all! My pinion preload was 15 in-lbs of rotating torque during setup, but I haven't dialed it in when it comes to the pinion nut torque. My understanding is that pinion nut torque doesn't affect the pattern as long as it's "pretty tight" and the preload is in spec. My carrier...

I appreciate the feedback. I used a set-up inner pinion race so I'm going to install the real race later. During set-up, I've been using 15 in-lbs of rotating torque for pinion preload, although I still need to dial the shim stack for this in to get the correct torque on the pinion nut. My...

I've been wrenching on my '97 XJ for a few years now and I've learned a lot from reading posts on this forum, so I appreciate any input! I'm in the process of re-gearing and installing an ARB in my Dana 30. This is my first time setting up gears. I think I am close, but would appreciate any...