XJ: TD 'Pocket Tourer'

[indertdxj]

The dual battery system is wire up so that between the picture selector (battery one, battery two or both) is a isolator switch. So when not charging batteries either one can be isolated from the other or from the alternator, allowing one to be connected to the starter/alternator independently of the other.

I thought that stiff shocks and rear bags may help with the sway....I have even found some shocks in the states with springs...Wonder if that will 'stiffen' up the back. You are right the back does experience a little sway.

[indertdxj]

I took delivery of some second hand shocks today (skyjacker platinum)[Thanks Neil!!]. Seam to be much better than old ones. When I fit them I will supply pics compared to old ones. I am sure there will be a ride difference as old OEs have no 'rebound' at all! The OE have done 285k!

[XJ 98]

Good work mate, am keen to see how it all turns out. Keep going !!

[indertdxj]

As I get more time I am going to do some more detailed write ups on some of the projects so far.


Dropping the transfer case is easy.

The biggest problem I had to over come is the transfer case is held in by a bolt and stud with nut. I cursed and swore because I was supplied with 4 bolts! So I discovered double nutting (never done this before) and out came the stud.

I borrowed a trolley jack (Gotta get one of those!!) and lowered the TCase down on it and installed new bolts etc...Don't Use a rattle gun, I did, stripped the thread

At this stage I discovered thread repair. I don't think that bolt is ever coming out!!!!!

[indertdxj]

Learnt two things today.

My new (secondhand) shocks are much bigger than old OE (see pic). Secondly they are harder to install than I thought. In fact I gave up and put OE back on.

The problem is that the skyjacker shocks are so hard to compress I can attach the top but can't push them up to put the bolt through the eye (on rear shocks).

Easy I though. I can push the shocks in a couple of inches while under the car so if I jack up the car and let the weight of the wheel pull the axle down a couple of inches I might push harder and make it happen.

Well lesson learnt. With a 3.5 inch lift the old OE bottle jack does not really even touch the chassis at full extension netalone pull the tyre of the ground.

So I think I need some one with a hoist or buy myself a high lift (damn!!) and jack up via the tow bar or something. I am working this weekend so it may have to wait until next week

Oh I think the cat likes the jeep!! Very interested in the shocks or was that the fluffy stuff coming out of the box they came in?

[Gojeep]

Cant use a hi lift jack in the towbar. Be too dangerous. You need to get yourself some 5 ton axle stands. Fit them under the frame after you have jacked up the axle under your axle. You could have also jacked the shock up using the bottle jack too.
Looks like you didn't read my write up before lowering the transfercase either as there is a warning about doing up those bolts and how to remove the studs. Just how are they kept in now?
I am also very worried about the length of those shocks. Have you compared the compressed length between them as they look a lot longer than the stock ones. What this means is if you have not lowered you bumpstops the exact amount they are longer in compression, they will bottom out before hitting the bumpstop. In the rear they can actually punch right through the bottom of the floor into the cargo area!
You are doing this build on a very budget level and taking a lot of short cuts which can come back and bite you big time. Things like even the brakes lines. Have you even checked if they will still reach at full down travel? You go offroad the first time and you could just rip them clean in half and have no brakes down a steep hill possibly. You cannot just go in gung ho with looking at everything.
Just saying this so you dont hurt yourself or some one else.

[indertdxj]

Yeh GOJEEP no problems I need reminding some times.

I filled the whole of the stripped thread an retapped the thread. Shouldn't be a problem as it is in tight now and shown no signs of moving, even to the point of being near impossible to get it undone (will definately need the breaker bar).

I am aware of the bump stop problem and it is definately on the cards as is extending the brake cables. I have a company car so the car is not a daily driver (depends which car is in the driveway so drive it sometimes). The car will definately not be going off road until such stuff is sorted.

I generally attempt stuff as time permits. I often work 6am through to 7pm and 6 or 7 days a week. Sometimes time only permits a hours work so I tackle something like the shocks instead of brakes because I don't want to have to bleed the system by myself in the dark etc...

Please remember that the OE shocks are OE length the other shocks are suited for a 4 inch lift (my lift is 3.5 so that makes them maybe .5 to 1 inch too long).

I have read alot of your sight but thought hey how hard can four bolts be to undo and do up?!?!?!