Well, it has been a while, but the XJ project had to sit on the back burner for a while and now its time to start. Before i even tried to get her passed under NCOP11 and VSB14, i had to sort out the terrible brakes. I had new rotors and Hawk pads but she would barely pull up. I have new caliper rebuild kits coming and also new rear cylinders. I replaced the booster with a brand new one but it made no difference. I also have a new master cylinder i am going to bench bleed and install as well as new braided lines. I also have a vac pump coming. I did some research online and for the XJ, it is highly recommended to replace the front pads with EBC Yellowstuff. I ordered some from the UK, but at $200 delivered through Amazon, they are not cheap. I fitted them this morning and what a difference. I would say about a 100% improvement in braking power over the Hawk pads. I will complete all the other brake improvements but i am happy it would pass a brake test now. The ABS kicked in as the front wheels tried to lock up.

After reading the VSB a few times, my understanding has grown but there still maybe some grey areas. I am dropping the tyre size down to 30" and getting new pro comp rims with 4.5" back spacing so that my track does not increase above the maximum 50mm. I am reducing the suspension down to 75mm including new standard shackles.
I am going to talk to an engineer about all the components that are already on the Jeep which i hope to get passed. Particularly the ACOS, quick disconnects, adjustable control arms with heim joints and tapped slip yoke eliminator.

The journey to the lane change test begins.....

Glad to see you haven't given up.
Good luck...

cheers

Thanks, and yes, never give up and let the bureaucracy beat you. I just received my new scanner in the mail yesterday. Its a Snap On MT 2500 with all the cables, connectors and modules to suit the 1995 XJ OBD1 system. I should be able to check the ABS system and cycle it for bleeding. Looking at Pro Comp street lock steelies at 4.5" back spacing for my legal wheels. Has anyone had experience with getting their ACOS passed at inspection, and can anyone recommend an engineer in the Perth area.

I submitted all my mods to the WA Dept of Transport. This included my mods for ACOS, adjustable control arms, raised suspension, 235 tyres, 22" light bar, profab tyre carrier, ARB lockers, extractors, Airraid intake, yellowbox speedo re-calibrator and a host of other mods.
I have received a reply:

Exhaust to comply with LA and LT4 (i want to add new extractors)

Part time locker to comply with LB2 (ARB air lockers)

Suspension to comply with LS3,4,5,6. (1.5" lift)

Roof and eyebrow height to be measured for standard and modified version.

Light bar to meet IB-132A (1 x 22" bar)

Protofab rear tyre not approved - obstructs geometric visibility of rear lights. Alternative required. (already fitted - supplied by Wooders)

Flexible flares and sunroof to compy with LH (Already fitted Bushwackers) (already fitted SFC XJ sunroof)

Verification that Yellow Box is ADR compliant and been tested or within +- 10% accuracy.

Bull bar to comply with CI-112C (this is an original factory Jeep bullbar)

This approval only applies to 235 x 75R x 15 tyres. (I have fitted these together with the factory rims)

Not a bad result and i think i can work within the rules. My question at the moment is: Can i use aftermarket lights on the protofab tyre carrier as it is already fitted. Is there a standard on the size of lights as i can get some slim LED lights that will fit on the rear bar.

Also note that the reply did not mention the adjustable control arms, ACOS, air bags, airraid intake, quick disconnects and winch that i had included in the proposal.

Cheers,
Alex

Cheers,
Alex

Odd that you'd need approval for 235/75/15's being that they're only one size bigger then stock...

I just put down all the mods i was doing to take the Jeep back into spec. The max roof height can only be 50mm above stock without going through all the hoops. I told them i was fitting 235 tyres which give about 8-10mm lift and i was putting on a 40mm lift kit. They approved those specs in writing and did not disapprove the ACOS i told them i was using to get the 40mm lift. The only thing they did not approve was the Protofab tyre carrier as the tyre blocks vision of the tail lights when looking at the rear from a 45 degree angle. Does anyone have any rules on size and fitment of lights to rear of car to meet ADR's as only slim line brake/park/reverse lights will fit on the carrier.
Also, does anyone have any official Jeep documents that say the Sport XJ had 1" higher springs as i would like to show the engineer the document if there is one floating around.

UPDATE: I have fitted the original alloy rims together with a brand new set of BF Goodrich all terrains 235/75/15's. I got the rims and tyres for 500 on Gumtree.
I have also lined up a set of Sport front/rear springs and shackles for 150. I am hoping to shrink it all back down in the next week or so and then check my roof height. I have brochures that spec a roof height without roof rack of 1625mm on 215 tyres. I have bushwackers fitted so i cant use the flare to floor guide.
Cheers,

There was a link posted on here some time back that gave the option to inout your VIN and it'd give you a full build sheet for your vehicle, I'd start with that....

Stock tyres for a pre-update Sport in Oz was 225/75/15...

If you do some searching on here you'll find I posted measurements for ride heights that use the bump stop plates as reference and not the usual hub centre to flare distance, this should help you some....