EugeneTheTJ's 2000 XJ Build Thread

EugeneTheTJ

Jeep Owner
Welcome, yall.

A brief introduction:
My name is Chris and I am an outdoorsman and Jeep addict. Some of you may know me from Jeepforum, ExPo, NAXJA, NC4x4, or IG. I have been around Jeeps basically all my life. In 2008, I bought my TJ which has become my rock crawler/weekend warrior/sunny day vehicle. My TJ also served as my DD until 2014 when I purchased by 2000 XJ.

The XJ started out as a mild build just to look better going to and from work and has since transformed into a solid overland rig and the flagship vehicle of Offroad NC. This thread will document the build.

I hope you enjoy!
 
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EugeneTheTJ

Jeep Owner
How it all started
Stock.jpg
StockSide.jpg
StockRear.jpg

4.0
4wd, NP231
Low pinion D30, C8.25
No Rust
Towing Package
3.55 R&P
 
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EugeneTheTJ

Jeep Owner
One of the first priorities was to rid the Jeep of the overwhelming cigarette smell. The headliner was replaced, the seats and carpets shampooed, and liberal amounts of Ozium were applied to the interior. Smoke smell was gone!
Headliner1.jpg
 
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EugeneTheTJ

Jeep Owner
Got my build sheet back from Chrysler...

Vehicle Description JEEP CHEROKEE SPORT 4X4 SPORT UTILITY 4-DR
Model Year 2000
Body Model XJ J H 74
Color PS5- Silverstone Metallic Clear Coat
ISD 07/21/2000
*M5 Prem Cloth Hi-Back Bucket Seats
-AZ Agate
AA4 Sport Value Group
ADAP Light Group
APAS Monotone Paint
AWHP Power Equipment Group
A20P 4.0L Engine(ERH)/4Sp Auto Trans(DGS
BASS 124 Amp Alternator
BCDS 500 Amp Maintenance Free Battery
BGAS Power Front Disc/Rear Drum Brakes
CADP High Back Bucket Seats
CBWS Highline Door Trim Panel
CDBS Reclining Front Seats
CFMS Rear Fold w/Removable Cushion Seat
CGGS Traveling Inboard Seat Belt Buckle
CGWS Next Generation Front Air Bags**
CKAS Carpets - Floor and Cargo Area
CKNS Cargo Compartment Carpet
CKTS Cargo Tie Down Loops
CKXS Plastic Liftgate Trim Panel
CLEP Front & Rear Floor Mats
CSAS Spare Tire Cover
CSC Cargo Compartment Cover
CSRS Passenger Assist Handles
CSSS Lift Gate Assist Handle
CUFS Full Length Floor Console
DGB All 4-Speed Automatic Transmissions
DGSS 4-Speed Automatic AW4 Transmission
DHAP Lock-Up Torque Converter
DHNS Command-Trac Part Time 4WD System
DHSP Floor Mount Automatic Shift Lever
DJKS Dana 30/181MM Front Axle
DMDP 3.55 Rear Axle Ratio
DRAS Corporate 8.25 Rear Axle
EAAC All Engines
ERH 4.0L I6 Power Tech Engine
GAL Deep Tint Sunscreen Glass
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GEEP Deep Tint Sunscreen Liftgate Glass
GFAS Rear Window Defroster
GNAS Rear View Day/Night Mirror
GNCP Sun Visors w/Illum Vanity Mirrors
GTZP Power Mirrors, Fold-Away
GVBC All Vehicles W/Power Mirrors
GXMP Remote Keyless Entry
HAAP Air Conditioning
HGDS Deluxe Insulation Group
JAYS Instrument Cluster w/Tach
JBFS Instrument Panel Black Bezel
JCDS 100 MPH Primary Speedometer
JHAS Var Intermittent Windshield Wipers
JHBP Rear Window Wiper/Washer
JJBS Dual Note Electric Horns
JJJS 12V Auxiliary Power Outlet
JPAP Power Windows
JPBP Power Locks
KDPS RADIANT SILVER MET. C/C - BADGE - CH
KGPS RADIANT SILVER MET. C/C - BADGE - JE
KRPS RADIANT SILVER MET. C/C - BADGE - 4
KTPS RADIANT SILVER MET. C/C - JEEP
KVPS RADIANT SILVER MET. C/C - BADGE - SP
KYPP RADIANT SILVER MET. C/C - 4.0L
K2ZS BLACK - MOLDING - BODYSIDE
K3LS SILVERSTONE MET C/C - FENDER FLARES
LAJS Headlamps On Warning Chimes
LBBP Courtesy Lamps
LCDP Map/Dome Reading Lamps
LDAP Underhood Lamp
LDBP Cargo Compartment Lamp
LHDP Headlamp Off Time Delay
LMAS Halogen Headlamps
LNJ Fog Lamps
LPSS CHMSL Lamp
MBKS Black Front Bumper End Caps
MBLS Body Color Front Bumper
MBSS Black Rear Bumper End Caps
MBTS Body Color Rear Bumper
MCAS Front Bumper Guards
MDA Front License Plate Bracket
MFBS Body Color Headlamp Bezels
MFKS Body Color Grille
MHAS Black Windshield Moldings
MMCS Rear Qtr Solid Window Insert
MMGS Belt Moldings
MMKS Body Color Drip Trough Molding
MNAS Black Door Handles
MNNS Body Color License Plate Brow
MWGP Roof Rack
NAA Federal Emissions
NBKS EVAP Control System
NFAS 20 Gallon Fuel Tank
NHM Speed Control
PS5 Silverstone Metallic Clear Coat
QS5S Silverstone Metallic Clear Coat
RAAC All Radio Equipped Vehicles
RAZ AM/FM Cassette Compact Disc Radio
RCRP 4 Speakers
RDDS Fixed Long Mast Antenna
SBAS Power Steering
SCGP Leather Wrapped Steering Wheel
SDAS Normal Duty Suspension
SHAS Front Stabilizer Bar
SHCS Rear Stabilizer Bar
SUAP Tilt Steering Column
TBB Full Size Spare Tire
TBLS Inside Mounted Spare Tire
TRLS P225/75R15 Wrangler RT/S AT Tires
TZAP Goodyear Brand Tires
WJW 15X7.0 Aluminum "Ecco" Wheels
WKBP Matching Spare Wheel
WLZC All Aluminum Wheels
XCYS Upgraded OBD-II Connectors
XJFS Tethered Fuel Filler Cap
XPFS Protective Coating and Remover
YAAS Build To U.S. Mkt. Specifications



Looks like mine was a super-late-model 2000
 

EugeneTheTJ

Jeep Owner
This was the first iteration of a lift on this Jeep.

BB spacers up front
HD Offroad Engineering Shackle Relocation
RC Lift Shackles

I thought I was onto something with this setup but quickly found that the shackle relocation kit only works for extremely stiff, tall springs and will KILL all others through premature flattening.

I urge you, avoid this mistake at all costs!
Shackle Relocation.jpg
SideLift.jpg
SideLiftComparison.jpg
 
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EugeneTheTJ

Jeep Owner
Shortly after that I got a stupid good deal on some tires. Definity (the Pep Boys brand) is made by Cooper and has the "Dakota" All Terrains. At the time they were transitioning to Dakota AT2s and I managed to get the last set of 31x10.50R15 ATs in the country for $19.99 a tire.

Considering the price, they weren't bad.
Tires1.jpg
 
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EugeneTheTJ

Jeep Owner
At that time I was still convinced the suspension setup would work. I replaced the springs with Crown replacement packs which kept a positive arch for a while but eventually succumbed to the downward pressure.

Here is new:
NewSprings.jpg
 

EugeneTheTJ

Jeep Owner
Shortly after that I threw on a roof basket I picked up from Cabelas and took the XJ on it's maiden voyage to Brown Mountain OHV in WNC. Jeep did really good. Only damage was a scraped up shackle from slamming it coming off a rock ledge.
CriagMtn.jpg
BM1_1.jpg
BM1_2.jpg
BM1_3.jpg
BM1_4.jpg
 

EugeneTheTJ

Jeep Owner
A short time after that trip I scored a killer craigslist deal on some JKU shocks and some XJ front tow hooks with tie in brackets.
TowHooks.jpg
JKUShocks1.jpg
JKUShocks2.jpg
 

EugeneTheTJ

Jeep Owner
More Craigslist sexiness. This may have been the turning point of the build for me mentally from mild XJ to full on overland rig.

ARB bullbar and a pre-96 XJ gas tank skid
arb.jpg
GTS.jpg
 

EugeneTheTJ

Jeep Owner
The skid plate took some minimal modification to get it on my 2000 but just needed some cutting and whacks with a BFH and it was good to go. I did develop a slight exhaust rattle afterwards between the pipe, the skid, and the shackle. The local muffler shop put on a new straight pipe with turn down and the issue was gone.
Exhaust1.jpg
Exhaust2.jpg
 

EugeneTheTJ

Jeep Owner
The Jeep's motor was tired, ticking, and marking it's territory wherever it went. It also needed a rear main but I didn't feel like addressing that until I took it for a rebuild so I chose to just address the leak at the oil filter adapter o-ring. Anyone who has done this can share in my pain and frustration of getting this stupid thing off the block. Nonetheless, I made it happen.
OilFilterAdapter.jpg
 
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EugeneTheTJ

Jeep Owner
Installed the ARB and decided to plasti-dip the rear bumper and side jugs to freshen it up a bit.
ForumRunner_20150625_211337.jpg
dipbumper.jpg
 
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EugeneTheTJ

Jeep Owner
The next few months apparently were experienced sans pictures. At some point I ordered a Warn M8000 through my man Rick at Quadratec and was able to pick up a free Warn recovery gear set through a mail in rebate they had going on. Winch pics shortly...

I also got more serious with the roof rack. Initially it had one extension on it and was mounted to the factory cross bars and tracks. When I realized how useful a roof rack could actually be, I decided to step up the strength of the mounts and installed 4 pairs of Yakima 1A raingutter towers with crossbars and added one more basket extension so that it spanned the full length of my roof. I also picked up an ARB 2000x2500 awning and mounted it up just before hitting up Overland Expo East.

Lastly, I decided I needed to get the spare tire out of the cargo area. I searched the interwebz high and low looking for XJ rear bumpers/tire carriers and just could not find anything that I was satisfied with. All of the offerings either looked like hillbilly fab junk, stuck out 2 feet, or weighed so much that you could literally hear the unibody screaming for mercy whenever the carrier was opened. Finally I stumbled across the offerings from Mark at Detours USA. I liked the simplicity of the Knucklebone and how lightweight it was compared to the heavy carriers. Thus, my Jeep ended up like this:
bwe.jpg
 
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EugeneTheTJ

Jeep Owner
I had an old set of KC Slimlites laying around that I installed on the ARB. I also picked up a pair of Trucklites to replace the old sealed beams. The difference was, pun intended, night and day.
trucklites.jpg
beautiful.jpg
trucklites2.jpg
 
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