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  #1  
Old November 20th, 2015, 08:26
F.N.G. F.N.G. is offline
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Expedition Build: Yellow Jeep XJ

Expedition Build: Yellow Jeep XJ

Now


This is my XJ Expedition Project.

Then


That was my stock 2001 Jeep XJ...

Backstory:

This is my first real Jeep Project.
When I got the jeep the previous owner had installed a 3inch Suspension lift with 2inch spacers on the front and 2 inch Lift Shackles on the rear, sitting on 31inch tires.
He provided me with a picture of the vehicle stock, before the lift.
Everything else was stock, including the broken Sway Bar links.
It had a death wobble from hell, which I found out the hard way on the highway coming home after buying it.
Once we hit 40 mph and a bump, it shock extremely violently until it came to a complete stop.
The experience was like an 8.7 on the Richter Scale, inside a giant paint shaker, while trying to steer.
Any of you that have experienced an actual legit full fledged Death Wobble in all it's glory know what I'm talking about.
And I still had a 2 hour drive home from the sellers house...
So it was at this point that I decided to strip it down and start from scratch in regards to the steering and suspension components.

How it sat when purchased




Phase: 1

We worked on it slowly, a little bit each day.
I don't have a shop, so we worked in my driveway, weather permitting.
We diagnosed many of the causes to the "Death Wobble" symptoms through trial and error.
One of the by-products of lifting a Jeep Cherokee 5 inch with no modifications or upgrades to the stock steering or suspension.
We would be removing the present lift in favor of a long arm lift kit.
I also started prepping for some of the exterior mods we would be putting on as well.


Front/Rear Bumper Removal





Parts List

I started ordering parts, and one by one they began collecting on my front porch.
Once my porch was full, parts began collecting inside.
We were living in a Jeep Parts Shop, and kind of interesting.
Here is my part's list bellow


Suspension:

  • RC 4.5 inch Long Arm Lift Kit:
  • Lifted high flex coil springs
  • Long arm Crossmember
  • Adjustable upper control arms
  • Adjustable lower control arms
  • Transfer case skid plate
  • Sway-bar quick disconnects
  • Adjustable track bar
  • Pitman arm
  • Stainless steel braided brake lines
  • Full Leaf Spring Packs
  • Performance 2.2 Series Shocks)
  • Rear Leaf Spring Shackles

Steering:

  • New bearings,
  • Moog upper and lower ball joints.
  • Currie Currectlync Heavy Duty Tie Rod and Drag Link.
  • Steering Box Brace.
  • Upgraded Heavy Duty 2.2 Steering Stabilizer.

Brakes:

  • New Rotors, Calipers and pads in front.
  • Drums and shoes in rear

Tune Up:


  • Air Filter
  • Champion Copper Plugs, and wires.
  • Oil change Mobile 1
  • Change transmission fluid
  • Coolant flush and fill
  • New Thermostat

Drive Train:


  • Slip Yolk Eliminator
  • Custom Tom Woods Rear Driveshaft

Exterior:


  • ARB Deluxe Bull Bar Front Bumper
  • Warn 8000 Winch
  • 2 IPF Spot Lights
  • JCR HD Rear Bumper/Tire Carrier
  • AJ's Super Rails Rock Slider
  • Roof Slider
  • JCR Gas Tank Skid Plate
  • Bushwacker Flat Fender Flares
  • Lower Rear Quarter plated on both sides
  • Underneath re-coated

Wheels:

  • 5 Cragar Soft 8 rims
  • 5 Goodyear Wrangler Duratrac 33x12.5 inch tires
  • Gorilla Chrome Lug and Lock set

Exhaust:

  • Custom exhaust from the headers back
  • Flowmaster Super 44 Muffler.


Miscellaneous:

  • Fixed wiring on driver side door, passengers can now control power windows again.
  • Fixed Rear Wiper.
  • New Windshield Wipers

Parts:


Phase: 1 Complete

Everything installed and tested.
After a little tinkering it road great.
Great articulation, good clearance, and no vibration at all.
The only thing steering/Suspension related that is still OEM in the vehicle is the actual sway bar itself, everything else was removed and upgraded.
The roof sliders had a bend to it, so we flipped them in the meantime until we straighten them out.
They are actually supposed to come down just above the door to protect the sides.
We had help from a shop installing the Lift and some of the equipment because we simply ran out of time.
The weather was upon us and we were working out of my driveway. So we put the project on hold and finished it in the spring.


Currie Currectlync Heavy Duty Tie Rod and Drag Link


Rough Country 4.5 Inch Long Arm Lift Kit


JCR Gas Tank Skid Plate


2001 Jeep XJ after Phase: 1 of the Expedition Build







More to come...

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  #2  
Old November 20th, 2015, 09:16
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DieselSJ DieselSJ is offline
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Re: Expedition Build: Yellow Jeep XJ

The 33's look good with that lift and the flares.
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  #3  
Old November 20th, 2015, 17:01
chesterbuggle chesterbuggle is offline
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Re: Expedition Build: Yellow Jeep XJ

How about some close ups of the roof sliders
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  #4  
Old November 22nd, 2015, 06:06
F.N.G. F.N.G. is offline
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Expedition Build: Yellow Jeep XJ

Bumper Integrated LED Reverse Lights

Installed LED spot lights in the JCR Rear Bumper, wired to my reverse lights.
Stock reverse lights were too obstructed by the JCR Rear Bumper to be of much use.
Decent lighting upgrade with major improvement for night visibility while backing up.

LED Reverse Lights







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  #5  
Old November 22nd, 2015, 07:09
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BlurpleXJ BlurpleXJ is online now
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Re: Expedition Build: Yellow Jeep XJ

Looks like a quality build. How do you like the Rough Country long arms? I decided to stick with short arm on a 4" lift, but went with OME springs and shocks.
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  #6  
Old November 22nd, 2015, 08:13
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Luke95 Luke95 is offline
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Re: Expedition Build: Yellow Jeep XJ

I have the rough country arms and so far so good. I am very happy with them.
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  #7  
Old November 22nd, 2015, 09:08
tom11919 tom11919 is offline
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Re: Expedition Build: Yellow Jeep XJ

RC Long arms with Currie Johnny Joints here. Ride is soooooo much nicer than stock links (went directly from 4" springs and stock links to long arms).
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  #8  
Old November 22nd, 2015, 09:18
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Luke95 Luke95 is offline
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Re: Expedition Build: Yellow Jeep XJ

Quote:
Originally Posted by tom11919 View Post
RC Long arms with Currie Johnny Joints here. Ride is soooooo much nicer than stock links (went directly from 4" springs and stock links to long arms).
This is what I have as well and love
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  #9  
Old November 22nd, 2015, 13:16
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Cottontail Cottontail is offline
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Re: Expedition Build: Yellow Jeep XJ

You had some body work done. Did you do that yourself? I'm referring to the second to last photo in post #1.

In the photo where you took the rear factory bumper off, I saw rust on the rear quarter panel, and also, you'd have had to drill out the rivets holding on the bumper cover brace.

It looks like a clean repair, and good color match on the paint.
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  #10  
Old November 22nd, 2015, 15:22
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Ian Christiansen Ian Christiansen is offline
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Re: Expedition Build: Yellow Jeep XJ

Near the top he says he did lower quarter armor. Maybe it's just covered up. Looks goood either way.
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  #11  
Old November 23rd, 2015, 07:44
F.N.G. F.N.G. is offline
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Expedition Build: Yellow Jeep XJ

Quote:
Originally Posted by chesterbuggle View Post
How about some close ups of the roof sliders
Per your request

Roof Sliders

I picked this rook rack up second hand from a guy parting out his build.
Solid construction, simple rugged setup.
Strictly for side protection purposes as a roof slider setup, obviously not intended for sufficient cargo use.

Roof Sliders






Last edited by F.N.G.; November 23rd, 2015 at 07:53.
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  #12  
Old November 23rd, 2015, 09:27
POSJ POSJ is offline
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Re: Expedition Build: Yellow Jeep XJ

The roof sliders look upside down to me...Would they fit flipped over?
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  #13  
Old November 23rd, 2015, 09:50
F.N.G. F.N.G. is offline
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Re: Expedition Build: Yellow Jeep XJ

Quote:
Originally Posted by POSJ View Post
The roof sliders look upside down to me...Would they fit flipped over?
Good eye. Yes the sliders were originally intended to be flipped, but
due to a bend in the sliders themselves the curve went opposite of the bodyline/roof.
Aesthetically speaking, it looked bad.
So until I could get them bent the proper direction we simply flipped them temporarily, and ended up liking the look of it so I kept it.
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  #14  
Old November 24th, 2015, 07:46
F.N.G. F.N.G. is offline
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Re: Expedition Build: Yellow Jeep XJ

Quote:
Originally Posted by BlurpleXJ View Post
Looks like a quality build. How do you like the Rough Country long arms? I decided to stick with short arm on a 4" lift, but went with OME springs and shocks.
Personally I like the long arm set up much better than the short arm.
Better articulation and an all around better ride in my opinion.
Plus added protection underneath is a plus.
All in all I like the Rough Country Long Arm Lift Kit.
The arms, coils and leaf packs are good.

However I have already replaced the quick disconnect sway bar links and will be replacing the shocks with a more rugged alternative.
The quick discos failed multiple times with light use and broke on me fairly early. And the shock bushings are bad after a year of use.
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  #15  
Old November 24th, 2015, 14:02
F.N.G. F.N.G. is offline
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Re: Expedition Build: Yellow Jeep XJ

Quote:
Originally Posted by Cottontail View Post
You had some body work done. Did you do that yourself? I'm referring to the second to last photo in post #1.

In the photo where you took the rear factory bumper off, I saw rust on the rear quarter panel, and also, you'd have had to drill out the rivets holding on the bumper cover brace.

It looks like a clean repair, and good color match on the paint.
We did have some body work done just on the lower rear quarter panels behind the rear bumper's plastic end caps.
I don't have a lot of experience with bodywork, so we had a guy that knew what he was doing help us out and do it right. Used thicker steal, so now it is armor plated on the lower rear quarters.
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