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I have a clunk in the front end on hill climbs. It happens in 2wd and more pronounced in 4wd. I have replaced lower control arms, upper control arms, Steering linkage. I have verified that the following have no problems: axle u-joints, front driveshaft u-joints, ball joints, hubs, track bar. The...

Don't trust Grade 5 bolts for this kind of application. The idea that Grade 5 are better because they "give" is a fallacy that keeps being passed around as gospel. I was an engineer and have two engineering degrees if that is a consideration. There are two common strengths associated with bolts...

Well, it's getting interesting. When I installed the pinion with all the original shims, and torqued the pinion nut, I couldn't turn the pinion. I added 0.008 to the pinion shims, and now the pinion torque is acceptable (somewhere in the 10-30 in-lb range. I then put in the carrier with the...

Before I took anything out, I did a pattern check and everything was reasonable. Both Drive and coast sides looked good. The only thing out of spec was backlash. After 130,000 miles, I guess there would be a little wear that would increase backlash. So your saying to use the same shims and...

I already searched and could not find an answer to my question. I have a 96 XJ with the high pinion non-disco D30. I am replacing all the bearings and the pinion seal. I am using all the old shims, since everything should go back in the way it came out. The only new piece is the pinion baffle...

We had a similar problem when we replaced a 231 transfer case on a 97 TJ, but it wasn't backwards, it was in the wrong position. The input arm for the 97 has an input shaft slot that is angled to the long side of the shifter arm. The one we had to replace it, had the slot either at right angles...

Be careful on Spicer's. A reputable off-roader friend of mine said that the owner of a driveline shop said that the Spicer's with the blue seals are made in China. Another member in our 4x4 club uses Spicer's exclusively, and has had to replace u-joints in less than a year. I've heard Neapco...

Go to any craft store, and get a tube of oil paint. It comes in every color you can think of and the price is reasonable. I usually use a yellow-gold, because it is a lot easier to see against the dark grey of the gear teeth.

I put on Flexy Flares. Got them from JC Whitney for $45 a pair. Several styles, but I put on the wide ones. Solid rubber, so they take a beating. Go to http://home.windstream.net/rsolomon/jeep.htm I have more pics if you want.

You don't have to have ABS in an XJ to need the 297's. I have a 96 XJ Classic built in July '96 that does not have ABS. First time I went to buy u-joints for the front axles, I got home and they were too small. Ever since, I just tell them I have ABS. They never believe you if you tell them...

I just got through troubleshooting a no lights of any kind problem on my 96 XJ. Even disassembled the front light wiring harness to make sure there were no shorted or broken wires. Turned out to be some broken and corroded wires in the ten pin connector under the airbox. I ended up cutting out...

I just replaced my exhaust manifold on my 96. Like you, I thought about the fuel rail o-rings. I bought the replacement kit, but figured I'd just put it back together and see if it leaked. It went together fine, with no leaks, so I now have an o-ring replacement pack to carry on the trail. As...

Here's the circuitry from the 96 Cherokee tech manual. From the ignition switch connector (C224 pin 2) it goes via a dark blue wire to splice S203 to connector C174 then to splice S124 to the PDC (still a dark blue wire). Power goes through the PDC at fuse 18 (15A) and comes out of the PDC on a...

To keep the needles in (whether we're using a u-joint tool, c-clamp, press, or hammer) we always fill the cups half way up with grease. That prevents the needles from falling in and being trapped in the cap. Broke a lot of needles before we started doing this.

Is the manifold plain steel? I have about a 2-1/2 inch crack in mine and was looking at replacing it. But if it's plain steel, I can MIG weld it. I have the equipment and skill to do that. If it's a special steel, I might not want to try it.

I just went through this scenario. Drove two hours to go off-roading and made it about eight feet before I noticed that the temp was about 230. Even with the electric fan running (I have a switch to force it on). Looking under the hood, it looked like the main fan was not spinning fast enough...

Do you have a tach? Is it bouncing also. I had that problem (bouncing speedo and tach on my 96 XJ) a while back. It was a bad ground to the cluster. I tried cleaning the connectors to the cluster, but that didn't help. I ended up running a ground wire directly from the cluster circuit panel to a...

I had the same problem at 55 mph. It appeared just after I did a front end rebuild. (New hubs, new u-joints, new ball joints) So I did the tire balance thing (BFG 32's). Then a front end alignment. Then driveshaft balance. I had a bent rear driveshaft. Then another wheel balance. Still had it...

I know the floor pans on my 96 XJ have a few holes. And yes, I did a search and have been reading the thread on the floor pan replacement. Here's my question. Has any body had success (or even tried) doing a repair with fiberglass. Here's what I was thinking. Get down to the floor pan and...

96 XJ. Every time I restart my XJ when the engine is warm(after sitting about 20 minutes), it throws a code and I get a check engine light. The OBD-II code says something about the O2 sensor voltage being too high. I replaced the number 2 sensor when I changed the cat. It is a Jeep sensor...