Stag’s street/trail XJ

Owners Name & City- Chance, Lahaina, Maui, Hawaii

(maui_xj on Instagram)

Make, Model & Year of Vehicle- 1990 Jeep Cherokee XJ Sport, 2 door


Engine- stock Renix 4.0l I6
-added a 140 amp alternator
-Trailhead Offroad cowl intake


Transmission- stock AW4


T-Case- NP231 w/ Teraflex “Super Short SYE”


Axles- D30, 4340 chromoly shafts / Ford 8.8 w/Detroit locker. 4.88 gears


Suspension- Rubicon Express 5.5” springs, Rough Country longarms, JKS shackles


Wheels and Tires- JK 17” takeoff wheels, 35” Goodyear Wrangler MTR-k


Winch- Harbor Freight 9k lb / steel cable


Favorite Trails- Poison Spider

Other - ‘97+ front clip conversion.



Story;

I found it on FB advertised as “not running, cranks but no fire, $500”. I figured it to be something simple, possible the CPK sensor.

I met the owner and started looking over the Jeep. Typical 26 year old vehicle; dirty interior, sagging headliner, junk in the cup holders, obvious lack of maintenance. But the price was right. I started diagnosing the engine, noticed no fuel at the schrader valve on the fuel rail.. went to turn on the key, and could hear the fuel pump come on and run for a few seconds… 🤔 interesting.

I offered him $450 and the seller accepted. I pulled it up onto my trailer, drove to the gas station, put 5 gallons in the tank and the engine fired up! The seller had run it out of gas, and didn’t realize. And yes, the fuel gauge reads accurately.

-The FB ad
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-Loaded up
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-The night I brought it home

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(Work-in-progress pics to follow)
 
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STAG

Beach bummin
Location
Pleasant Grove
Cleaned up inside the fenders, and cut out the “death seam” to help clear some larger tires.
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Put on some 3” coils, lift blocks and 35’s I had left over from a different vehicle (the ZJ I bought from Dan) Money was tight during these years and I really didn’t have enough extra cash to do what I wanted to with this Jeep.
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From this point, life got in the way and the Jeep sat inside my garage for about 3-4 years straight, pretty much untouched. Didn’t have the money or the motivation to work on it much.
 

STAG

Beach bummin
Location
Pleasant Grove
Fastforward to 2021; I got a new job and money was better. I got out of debt and finally had some extra cash to throw at this thing. Only problem was, never had the time! My job was pretty much a 7-day-a-week commitment and if I wasn’t working, I was attempting to get my house curb-appeal bumped up in order to get it sold. I finally got the house sold and now I’ve quit my job and I basically just work on the Jeep now 😂

First mod; install a Teraflex SYE to get rid of the slip yoke on the NP231.

(Future pic here)

Then came an addiction of ordering parts to get rid of the sh*tty lift situation I had going on. First up, longarms. Then after that I picked up some Rubicon Express 5.5” lift springs. Is it too tall at this height? Maybe. I’ll have to wheel it a bit and see how I feel about it. The 35’s have a lot more clearance now though 😂

Along with the 5.5” springs, I installed Bilstein 5100’s and extended brake lines. I had a set of swaybar quick-disco’s I had bought from FB marketplace several years ago, and finally threw them on. Here you can see the “death seam” gone much better than in the pictures in the last post.
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I found a Ford 8.8 rear axle on KSL out of a late ‘90’s explorer and picked it up. The guy had 4.88 gears for it and a D30. I picked them up and @skippy installed the gears for me 🙌🏻 The guy with the 8.8 also had some brand new D30 4340 chromoly axles so I picked them up from him too and installed them in my D30. I’ll post a pic below of the seal # that you need to buy and install inside the diff housing when converting these Central-Axle-Disconnect D30’s to a 1-piece passenger shaft.
 

STAG

Beach bummin
Location
Pleasant Grove
Prepped, primed and painted behind where the rear bumper will go. I wanted to build a custom bumper but with my current time-constraints I did not have the time to build one so I ended up picking up a Smittybilt w/ tire carrier. Don’t mind the overspray around the bottom corner edges, that will be handled next 😎
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STAG

Beach bummin
Location
Pleasant Grove
I then removed the nasty stained 31 year old carpet to find a fairly decent floor.
There was one rust spot right above the muffler to cut out and patch back in. I figure the muffler got hot and cooked away the protective paint. Maybe even some moisture had got in and saturated the carpet. 🤷🏻‍♂️
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All cut out-
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Primed-
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Painted-
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STAG

Beach bummin
Location
Pleasant Grove
Also started working on a “roofrack” really just to mount lights to. I have a small obsession with lighting. There will be quite a bit on this Jeep. These are the aluminum bends that Carl bent for me as I don’t have a bender right now. This is just some mock-up and figuring out where and how everything will sit.
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Diesel_Zuk

Well-Known Member
Sounds like my old neighbor, her boyfriend couldn't get the lawnmower started so she asked me to look at it. He ran it out of gas and couldn't figure out why it wouldn't start!

Cool build though, was awesome to see in person, and can't wait to see how it turns out. Is that a HF winch?
 

STAG

Beach bummin
Location
Pleasant Grove
Sounds like my old neighbor, her boyfriend couldn't get the lawnmower started so she asked me to look at it. He ran it out of gas and couldn't figure out why it wouldn't start!

Cool build though, was awesome to see in person, and can't wait to see how it turns out. Is that a HF winch?
It is. One of the pre-badlands ones. I’ve heard decent things about them and I was poor when I was shopping for them ha. I think I got it with a 20% off coupon for like $175 new.
That winch mount might be too nice for an XJ. It's really clean and tight.
It is tight ha. I was surprised everything has fit so well so far. There’s clearance everywhere, but in some places not much, < 1/4”. I actually cut that plate out the old school way, a hand drill and a 4.5” angle grinder with a cutoff wheel ha… in my basement 🙃
 
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STAG

Beach bummin
Location
Pleasant Grove
So since I’m running the 97+ front clip and it’s harness, the harness connector plugs are different between 1990 and whatever year the Jeep I got my grille and harness from was so I cut off the old plugs and converted them both to a new connector. I extended the wires on the Jeep side a few inches to make it easier to work with.


I don’t know why, but in the old harness on the ‘90, there is a constant-hot 12v pin. I can’t figure out why they would need that. There is also a green w/black stripe wire that I have no idea what it goes to. I don’t have a fog light switch so I don’t think fog lights 🤷🏻‍♂️ I’ll have to look up some diagrams.
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STAG

Beach bummin
Location
Pleasant Grove
JKS shackles. I didn’t realize with lift springs you have to run longer shackles:( that added unwanted height, but we’ll see if it’s a nightmare or not. If it is I’ll drop to a smaller lift leaf spring
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bryson

RME Resident Ninja
Supporting Member
Location
West Jordan
I love what you've done with the combination snorkel/lightbar/roll cage! So creative!

This may be obvious, but the longer shackles are required in some cases because (most) lift manufacturers use springs with the same length (as measured along the spring to negate arch) as stock, but with more arch (your lift, good sir). This effectively makes them shorter (straight-line eye-eye measurement). Stock shackles are short and can't compensate :handlebars: for the difference.
 

STAG

Beach bummin
Location
Pleasant Grove
Yeah it does make sense. Just not something I had the foresight to think about until I bolted these leafs up to the stock shackles and watched them hit the body metal behind the shackles 😂
 
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