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  #43  
Old 04-05-2017
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Always loved those rims!!
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  #44  
Old 28-05-2017
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Been having a couple of issues with the old XJ, so haven't been driving it much. Current thing that's doing my head in is it keeps blowing the 30amp fuse for the ECU/PCM after about 10-15mins running. Can be idling, can be driving, doesn't make a difference if there's load on the motor or not. But as soon as I replace the fuse it starts back up first go and runs perfect.

Anyone got any ideas as to what it could be? Have a spare car for parts so am tempted to swap across the ECU/PCM to see if there's a short-to-ground that it's getting stuck on, but otherwise can't work it out.
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  #45  
Old 27-05-2018
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Default XJ: Fraz's Not-so-budget Budget Build

So lots has been happening with the old girl of late.

First things first, I finally figured out the overheating and fuse issues. 30amp fuse for PCM kept blowing because the post-catalytic converter O2 sensor wiring had worn through on the tailshaft and was shorting out the PCM. I mustn't have tied it out of the way when doing the drivetrain swap from one to the other. Overheating was caused by a partially blocked radiator which made it difficult to diagnose. Would overheat on the highway only, but at random. Never overheated around town. Now has an 85* thermostat, new clutch fan (old one was incorrect) and radiator, and it barely goes above 90 when climbing a hill while towing half a tonne.

Now for the current project - JK Wrangler Axles.

I picked up a set of complete disc to disc axles from a mate who had upgraded to Ultimate Dana 60's. It's a D30/D44 combo from an Overland, and had been recently regeared to 4.56:1 ratios. I'll be running the original 18" Overland wheels with road tyres as day-to-day driving wheels, and will pick up a set of 16" or 17" base tyres to throw some 33's on for offroad.

Basically, the JK Axles are 120mm wider from wheel mounting face to mounting face compared to the XJ axles. I've already spoken to an Engineer about the swap, and as long as I maintain the ABS and get the proportioning correct for the brakes (will see about fitting a JK Master, otherwise a larger master and ZJ Proportioning valve) there should be no issues with getting the wheel track increase, tyre increase and ratio change engineered. I should also be able to raise the GVM a little bit given that the JK Axles are rated higher than the XJ's. If not, it's no biggie.

Anyway, started the rear axle today. Removed all the old control arm mounts from the D44, cleaned up the housing and welded the new spring perches to the axle tubes after a LOT of measuring. Will also be fitting a Uneek4x4 Weld-on Truss (sitting on the diff in the final photo) to the rear axle before it's fitted to the car.

Dana 35 from my old black sport for reference and shock mounts


Unboxing the JK Axles


Checking the Pinion angle relative to the spring perches on the Dana 35



The Dana44 axle before bracket removal


Mid bracket removal


Just the LCA mounts to go


Leaf Spring perch welded to axle tube


Soon to be Finished Product


I've left part of the bump-stop bracket from the original JK mounts as it holds the handbrake cable. I'll need to get custom handbrake cables made up, as well as hard lines for the rear brakes. I'll also need to drill and tap a hole for the rear brake line to bolt to, as the original breather now sits under the truss on the left side of the photo.

Now just to play the waiting game for the Artec JK2TJ Front truss setup to arrive, then I can start getting the front mocked up. Hopefully I'll have the rear finished by then so I can get it all into the car in one go. We shall see...
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Last edited by fraz; 27-05-2018 at 12:43 AM. Reason: Got the photos to work
  #46  
Old 31-05-2018
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I was wondering about JK diffs in xj a while back, should be a good thing & legal with the right engineer. I like the digital protractor, would make getting the right angle easier for a half blind & more than half way stupid old bloke.
  #47  
Old 23-07-2018
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Any more progress fraz?
  #48  
Old 04-08-2018
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Quote:
Originally Posted by oldon View Post
Any more progress fraz?
Yeah, just been too busy to put it up. Will do an update tonight

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  #49  
Old 14-08-2018
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Have been absolutely flat out with this thing. Trying to get it all finished before the end of the week.

For starters, got the front all mocked up and ready to go, then ran out of time to actually weld the mounts on that day. Welded the front coil mounts and swaybar brackets together, then realised I needed to do that on the diff, so cut a slot so it would fit to the diff without having to undo a heap of weld. (I'm not great at reading instructions)

Next, ordered a 1310 D44 diff yoke, only to be sent one for a TJ instead of the JK one I asked for. Shit happens, but I'll have to sort something real quick.

Started putting the diffs in tonight after work. Got the rear in, the rear bolted up stupidly easy. Used ZJ rear brake lines (had to drill them out to suit the JK banjo bolts) and they connect straight up to the XJ hard lines. (Will get pics tomorrow)

Welded the front coil mounts onto the front diff, and tomorrow the front diff goes in. Hopefully the Panhard and bracket turns up in time. Will be using a JK pitman Arm and steering linkages. Not sure how I'm going to get the steering damper to mount, but I will.

Anyway, that's where I'm at. Once I've got more time I'll finish off the truss and do a little more to the diffs, as well as a full write up on costs, parts list and everything. Right now I'm just too time poor trying to get this done while packing to move to Melbourne.

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