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Don't stress so much over it. Once you do the conversion you'll never look back. Better stopping power, longer lasting components and an easier job of replacing parts.
Some need the proportioning valve, I didn't and have outstanding stopping capability. The biggest benefit I saw was off-road...
It should be 'pretty' quiet but not totally. The sound you are hearing, the clicking, is probably the two sides operating independant of each other (aka un-locking) and the teeth clicking past each other. Most lockers will make that noise in a turn. FWIW, I can only hear mine with the windows...
You could bolt or weld and be fine. There isn't a ton of tension on it.
Have never heard of that bracket coming loose but it doesn't surprise me.
Mitch
What year XJ? If it is the late models it could be the evap. Definately get a vacuum pulled on it because moisture can really do a number on it. If it is truly freon (R12) you'll want a vacuum anyway because you will replace with R13a and the two don't mix if moisture is part of the equation.
maybe just stating the obvious but what about some Lock-tite? Since I did my gears I have often thought that the adjusters were the weak spot on the 8.25 and wonder how they stay in even with the right amount of torque.
Was the wine the indicator to you that they had loosened?
Mitch
Man, hopefully you don't take her back. You sound too calm about it like you're willing to 'try again' with her. Remember, once a HO always a HO. Be very thankful that you didn't have children with this woman which would preclude you from walking out of her life for good.
While it sucks to...
I got mine from AJ a couple of years ago and specifically requested a 'width' that would protect out to the door handles. I think he makes them that way standard now. the only body parts that are still vulnerable are the rear quarters.
For $700 you could make it a convertible, beat the snot out of it, trail rig if the a-pillars are busted. Or you could buy it and part it out over ebay and make some money on it...
When I bought my wifes 98 Cherokee Country (w/ABS) we got a screaming deal because it had a serious whine out of the rear D35 (98, 4.0, 242, 60K, immaculate for $4200). Swapped in a $100 D35 non ABS and pulled the relay and have had no problems at all....