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Discussion Starter · #1 ·
I recently purchased a 1996 xj sport and set off on a budget toy to tinker and offroad with.

Problems:
-cracked exhaust manifold
-oil leak from oil filter adapter
-possibly oil leak from rear main
-interior lights don't work
-power locks don't work
-power mirrors don't work
-window seals
-door seals
-check engine light
-tires

Parts I already have or on order:
-APN headers(qc hold)
-oil filter adapter o rings
-rear main seal
-thermostat/radiator hoses
-serpentine belt
-window seals/door seals
-motor mounts
- after cat oxygen sensor (check engine light)
-Ome 3" lift(coils, leaves, shocks, stabiliser damper, quick disco sbe)
-adventuro 31x10.5x15 (they were cheap)
-fuel filter, oil filter, spark plugs


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Discussion Starter · #2 ·
Where I am at as far as parts replaced:
- fixed the temperature gauge (disco sensor)
-spray painted the hood and pass side bare metal showing
-replaced window seals
-replaced spark plugs
-attempted at breaking the bolt on oil filter adapter, no luck.
-started on lift


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Front came out fairly easy. Didn't need a strut spring compressor to take it out but definitely needed it putting the new ones in. No broke bolts, no power tools. I sprayed pb blaster on all the bolts I saw earlier that week. I installed the steering stabilizer when I had everything out and that was a bit of a pain but the pitman arm puller and pb blaster did the trick..

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I started on the rear today while waiting to figure out what shocks are going in it and got the rear shocks out clean with no broken bolts.

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I loosened the bolts on the rear leave springs, those bolts were interesting and I haven't gotten the leaf out yet. Apparently, you must remove the shackle bc the bolt for the rear eye is too long soo.. I started working on that and it was uncooperative so I sprayed all that with pb blaster and I'll come back to it when I get more time (I really only have time to work on it when the family is asleep or weekends assuming they aren't interrupting me or having me run them on errands.. )

This jeep has been in west texas an has very little rust which has been awesome. I've not encountered any issues with broken bolts but I still have a few left to take care of. So that's where I am at in this.
 

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Discussion Starter · #3 ·
So this is where I'm stuck. Rear leave spring shackle bolt. Went to take the leave spring off and surprise! It's too long to pull out.. so the shackle needs to come off, I've gotten it to turn a couple times as you can see but this thing is beastly. starting to strip the bolt. Kept poppin when I was putting my back into that breaker bar. Alreafy pb blastered it lastnight and this morning after moving it a 1/8-1/4 turn.. Any ideas?


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Did you get em in?

I bet you could make the ball joint press work if you have something flat on both sides to distribute the weight across the bushing. You could also try prying open the leaf spring hole with a flat head. My OME springs came with poly bushings so I didn't have to do this step but I did replace front axle upper bushings which are very similar. I froze em for a couple hours and used the ball joint press to press em in.
 

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Discussion Starter · #6 ·
I tried the prybar/screwdriver way with no luck. Im going to home depot to make a makeshift press w a threaded bar, nuts and floor mount for pipe. I may also freeze them to make sure the lil suckers go in easier and grease them up.
 

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I've used my vise and large sockets to press in bushings.
 

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Discussion Starter · #8 ·
My largest socket is a 7/8". I don't have a large tool collection but it seems to be growing through this project. Haha. I figure it'd be less than 20$ and im sure it'd cost that to have a machine shop press them in..
 

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Where did you get the leaf springs and how much did they cost you?

Looks good, OME has some nice stuff I hear...
 

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Discussion Starter · #11 ·
The leaf spring came with 3" kit from jeepinoutfitters so im not sure how much they are individually.

The press I made worked pretty good. I got the idea from another thread possibly on another site.. Greased it up a lil after freezing them and squeezed it till it was close on the other side and used a dead blow to pound that bad boy the rest of the way in there.. I hit it alot and hard.. dead blow head was pretty hot.

I'm working on getting the rear done as fast as I can to get it on the ground and see the height in the front to figure out the right shocks. (I can only work when my kids are sleeping..) I'm pretty sure the long travel shocks are going to be it but I could only measure with it on jacks and jacking the front axle up (inaccurate). So, working diligently on getting the rear end wrapped up. I think the regular shocks should be fine for the back as there is no aal or drop bracket as well as the leaves..
 

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Discussion Starter · #12 ·
Sooo I have the passenger side leaf in, working on driver side leaf now.. this is the "makeshift press" I used for the eye bushings.


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Discussion Starter · #13 ·
Note.. the makeshift press is only a one time use I guess.. threads stripped out.

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So I moved on to my old trusty red... thankfully I got it started before all the usable threads were gone..


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No better way to release some stress! :) Pound away. :thumbsup:
 

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Discussion Starter · #15 ·
Very true.. but I beat the pig snot outta those things.. at one point I was wondering if the bushings will suffer from my beatings.. haha eventually I figured out a good angle to lay the leaves on the ground (eye on the concrete instead of propped up off the concrete), 3 wacks late and done.. now just gotta wiggle the old bolts and leaf out and put this one in, put u bolts on and drop it down to measure the fronts distance to see which shocks to go with..
 

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Well until then, keep on posting pictures. We love pictures, especially progress pictures. :thumbsup:
 

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Discussion Starter · #17 ·
The second one is always easier.. having some trouble lining the leaf center pin and hole up in this one as well.. haven't gotten it in this side quite yet but both leavves are in.



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That's quite a bit of lift. What's your shackle angle like?
 

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Discussion Starter · #20 ·
I loosened the shackle enough for it to move but I haven't tightened it yet. 5.5" is the difference feom before and now. Im sure it'll come down as they are broken in.. I am just setting it on the ground now to get measurements in front to see the amount of play I would have with the shocks that came with it.. (2" at ride height before topping out)
 
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