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If you have some patience, a press, a bearing plate, seal puller and are the hands-on type, you can rebuild it for less than around $200 in parts... If not, think of it like a $600 labor bill plus other costs previously mentioned (shipping, etc..). I tackled mine and it really wasn't all that...

My $0.02; I love using this Corroseal stuff. http://www.corroseal.com/

Dude, this is a rad build. Props to you. Huge fan of your work over here.

Circling back around to this, I decided to throw some new plug wires and plugs in it while doing an oil change. Believe it or not, that was it. So it was either a plug or something up with one of the wires. Truck runs great now and hasn't skipped a beat on starting since. I still think I...

So the harness from the battery to the starter looks fine, but I did notice that where it's crimped or pressed into the factory battery terminal, there is a fair bit of oxidation on the exposed copper stranding of the starter's 12V wire. I wiggled the connection around to sort of break that...

I took a wire brush and thoroughly cleaned both sides of the contacts and the nuts that connect to the starter. My battery connections, although a little tatty, are holding very tight and the battery itself isn't all that old. No other issues with electronics/lights/etc... in the rest of the...

So just to make that task a little easier, I opted for a new starter. Started fine this morning but when I left for lunch on my break, sure enough, it did the same thing it had been doing. So I guess it's not the starter after all. I'm suspecting a leaky injector now - planning to pull plugs...

Well it's nice to see a consensus on the possible culprit. The starter is one of the older electrical components still in service on the truck, so it's a good suspect. Not to mention, it's got it's fair share of oil and dirt on it. I've never had one partially breakdown like this, but it makes...

The essentials: 1997 XJ - 4.0L 5-Speed - 194k - motor all stock. So this random issue started a few weeks back and it's slowly becoming a more and more common occurrence. Essentially, when you go to turn the key to start the truck, it will turn over just fine but then sometimes it'll suddenly...

A lot of good information in here - allow me to add some pictures. I've had a lot of experience with my AX15 (factory installed from my 97 XJ) over the years. Although its a really simple/strong little 5-box, I've had a couple reoccurring issues; I wonder if you've run across this before...

...actually, as I was pondering over this last night in bed, I realized that my transmission doesn't actually have a vent. I know the factory vent is located on the shifter base, but I'm running a Hurst short throw. I've always assumed that it would venting through the pivot ball area, but I...

^ hey-o, there's an idea. Will definitely look into it

What's the consensus on those out there with an AX15? Are you leaking or not? It seems every build thread I see with another 5-speed owner, there's is leaking too. I recently had to get inside mine to replace a 3/4 fork and in the process threw in yet ANOTHER rear tail seal since mine was...

If you paint over rust with something like Rustoleum paint, you'll get rust again. You need to chemical inactivate the iron oxide. I've been using Corroseal here lately. Everyone should have some of this around... http://www.corroseal.com/rust/photos.aspx Here is a TJ frame/suspension parts I...

Doesn't have to be.... I run this Active Suspension kit on my XJ and it's great for hauling loads and taking jumps. I love it for the simple fact that I can run a softer leaf and adjust the pre-loading and height based on what I'm doing. Not to mention it actually pushes droop while flexing...

Looks great! I'm a fan.

Great write up and good pictures. Looks solid. Grab you some trim restore/dye and bring that door trim back to black so it all matches.

For the issue with the 4.0 and it's header, I don't think there is any issue with heat transfer through the bracket to the block. As for a turbo application, this is a typical OE equipped component and is always affixed to the compressor housing; which doesn't hit nearly as high of a temperature...

Has anyone ever tried securing the header to the block at the collector or something similar? I have a ton of experience with tubular stainless turbo manifolds cracking due to the turbo weight and aggressive drivetrain shocks/vibrations (i.e. drifting) and that was always the solution. flex...

I sourced all of my parts through Southern Gear. I recall my kit being from TransStar and cost about the same; still drives; lol. Call the guys down there if you want to ask some questions. I had two numbers in my phone - not sure which one it is; lol. 770-435-1461 / 770-435-4774