Nolan's 94 XJ Build


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Old 05-28-2013, 08:36 PM   #1
nolan
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Default Nolan's 94 XJ Build

I just got this jeep about 3 months ago. It was as stock as it could be. It is pretty straight but wasn't maintained for the past few years. Most of the work I've done so far has been under the hood and in the dash.

Under the hood, I've replaced the water pump, almost all the hoses, the s belt, and installed a cold air intake.

In the dash, I've fixed the radio, replaced lights, swapped out the dummy gauge setup, and fixed the glovebox and headlight switch.

I pulled the rear glass out and popped in a piece of defroster glass - kind of nice to have in CO.

I also ditched the rusty steel wheels with bald tires for a set of aluminum rims with 30" bald tires that I picked up for $100.

What's next? Install the 4.5 RE lift that I got for next to nothing!






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Old 06-01-2013, 08:33 AM   #2
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Default Two doors Rock!

You have a nice jeep to start with. Is yours a auto or 5-spd?

Once you get going with the lift and bigger tires you will want to do the brake mod. (96' brake booster) Stopping can be kind a scary with the single dio booster.

Nice score on your lift.
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Old 06-01-2013, 08:49 AM   #3
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I've got the 5-speed. Love having manual transmission but the 3.07 gear will suck as the tires get bigger.

The dual reservoir is on my list along with upgrading the steering. I just need to get out to the junk yard again.

Thanks for the compliments. The biggest envy that the 4 door group has of my 2 door is they are limited in how much they can cut in the back due to the rear doors. I envy the four door group when I have more than 2 people in my ride.
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Old 06-01-2013, 07:44 PM   #4
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Default 2 Doors

I love my 2 door. The one thing I am looking to do is get the rear split window so that when it is hot I can set-up air flow through the cab. I am just keeping my eye out for those. It is kind of bad when you get some of the parts to work on it and have no time or money to get things done.

My XJ gearing is the pits with the 5 spd. and 33" tires. That is why I don't want to wheel anything serious, but there are some pretty nice trails that are rated in the middle up here.

When are you getting started on that lift? (I would start spraying all the nuts and bolts with penetrating oil ASAP).
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Old 06-01-2013, 08:57 PM   #5
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It's going to be a little while before I put the lift in. I have bushings to replace, johnny joints to rebuild, shocks and brake lines to purchase, and a few other decisions to make. Most of the timing comes down to available funds. I could skip a few meals to make it happen but the rest of the family doesn't think that's funny.

I hear you on the bolts. I'm going to get my PB Blaster on.

Talk to me about the split rear window. I have not heard of that. You have me curious.
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Old 06-01-2013, 09:48 PM   #6
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Default Split window

If you look at Stiflers 2-door http://www.cherokeetalk.com/forum/f2...-2-door-16280/ His has the back windows I want.
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Old 06-01-2013, 10:36 PM   #7
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I borrowed one of stiffler's pics to demonstrate what you are referring to. Yes, I want some too!


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Old 07-14-2013, 10:58 PM   #8
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I scored a pair of vented side windows for $20. They needed to be cleaned up a little but overall the glass and rubber were in good shape.

I had only replaced one other window in my life and that was the rear window on this rig (switched plain glass for defroster glass). That job went fairly smooth so I figured this one would too. For the most part, it did.

To remove the existing window, i used a plastic tool (carpet tucking tool) as a pry bar.

It is extremely helpful to remove all plastic interior trim in the area (it will be a lot of trim and requires a Phillips screwdriver and a couple Torx bits (I think it was a 25 and 55 Torx). I did leave the trim at the bottom of the window on but it would have been a little easier had I removed it.

Once I removed the plastic trim, I jumped inside the back of the jeep and started working the rubber in the upper rear corner. I had to get the rubber around the window flange and push it towards the outside. Once I got a bit of the rubber loosened up, I jumped outside or the jeep and pulled that rubber all the way through. Once you have a bit of the rubber pulled through, you and use your plastic pry tool to finish working the back side and top side. If you have the back and top side pushed through, you and probably tug on the glass and the front and bottom sides should release pretty easily.

To put the glass back, it is pretty much the reverse of install. You will need to start with the bottom and rear sides beginning with pulling the bottom corner in. You may want a second person at this point to hold the glass in place (I almost learned the hard way). Use your pry tool to pull the rear and bottom rubber through. As you do, be sure the window is seating down and to the rear properly. Once you have the rubber pulled through on those sides, do the front side and finally the top side. The most difficult parts will be pulling the rubber through at the corners.

When you finally have all the rubber pulled through, bang on the outside trim with your fist to make sure the window is completely seated. Do this all the way around the perimeter. Next, use your thumbs to check that the rubber is fully seated all around the inside of the window.

You should probably plan on 2 hours per window. I got mine done a little quicker but I already had most of the plastic pulled and had recent experience with my rear window.

Do not use metal tools - you will chip your paint and tear your rubber seal.

If you end up learning something that makes replacing glass easier, share it here. We can all learn from each other.


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Old 07-14-2013, 11:00 PM   #9
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Pic with the windows installed.


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Old 07-15-2013, 02:33 PM   #10
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Default Nice Work!

Nolan, I am so jealous you have your windows in so quickly. They look real good.
I did not touch my XJ this weekend like I said. (Just got busy with other things). When we put my first one in we used plastic pry-bars too and just stuck a screw driver in to hold while we moved to the next tuck. (Kind of like putting on a bike tire.) Did you do yours by yourself? I have my brother in-law and son helping me when I did mine and it was easier with the extra hands.

Are you planning on lifting your jeep soon? I am getting closer to where I will have the time to go exploring up in those Rockies we have in our back yard. My son is going up camping nere Como just west of Jefferson. The area has some nice trails in the back country. (I am just jones’ing you know).
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Old 07-15-2013, 05:43 PM   #11
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I did the first window by myself. I had already pulled the plastic trim for another project I am doing on the left side so that made access to the rubber really nice. The only plastic left in the area was the plastic below the window. I did pretty well getting the glass set in the opening after almost dropping it the first attempt.

For the second window, I did get my 15 year old to come hold the glass in place while I got the bottom and one side done. After that, I let him crawl inside and get his grove on with the rubber. I ended up raiding the kitchen and found a second plastic utensil so we could double team it.

My rubber was pretty pliable so it didn't fight me too much.

The job is a pain. If it goes easy, there is probably something wrong.

My next glass quest is to find a factory tinted rear defrost window. After that, door vents to replace the fixed vents.

I have to save up a few more bucks to finish the lift. I need to replace a ton of bushings, rear shocks, get extended brake lines, and find a decent set of tires.

I really want to hit the trails. I went out once with my 30" tires and stock suspension and it didn't really work that well. It doesn't help that the leafs are frowning me.

I might end end up selling a rifle to finish financing the suspension - I have a Browning 270 Winchester BAR that I love but never use. I should be able to get enough out of that to get the tires and suspension done and have money left over for other projects.
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Old 07-15-2013, 07:28 PM   #12
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Never done one myself but could the old "rope trick" work here? It's what we did on all the VW's, takes about one minute once the window is in place...the side and back windows took less time to take out. lol
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Old 07-15-2013, 08:31 PM   #13
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Default Using Rope

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Originally Posted by DWtim View Post
Never done one myself but could the old "rope trick" work here? It's what we did on all the VW's, takes about one minute once the window is in place...the side and back windows took less time to take out. lol
The reason I would not use a rope is that I would be afraid of pulling the rubber which is older and dryer with it and tearing through the rubber and ruining it. (When I replaced the back window on my F150 I tried the rope and had that problem). That is why I used the plastic pry bars and took my time on mine.
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Old 07-16-2013, 11:01 PM   #14
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Trying to work a deal on some bumpers, winch, lights, and a cargo carrier from an XJ that's being retired.

I haven't seen this rig yet in person but the dude claims to have a Chevy 350 shoved in there. Shoot, screw the bumpers...I should buy the whole rig.




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Old 07-17-2013, 08:26 AM   #15
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Definately digging that rear bumper...


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