1999 XJ DD & Weekend Warrior

[NW99XJ]

More to come... Stay tuned....

[bluedragon436]

Glad to see that you are getting her back up and going again... Once you get her back on the road and able to enjoy her again, you'll forget all about the down sides and the negative happenings!!

[07Negative]

Dude, that's nuts!

[cantab27]

yep shes a good drive home when they snap.........

[NW99XJ]

So that was all back in May, after all the prep was done, I VERY CAREFULLY drove it sans-track-bar the few miles to my buddy Brandon's house.
(that was fun)
He's a much better welder than I am, and I would trust his work more than my own for this critical repair.
The plan: .....to re-mount the old Ruff Stuff bracket, and to reinforce the area some.
The results:
The Jeep was staged up in the driveway and he began to get to work:
http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/IMG_3392.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/IMG_3392.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/IMG_9430.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/IMG_9430.jpg.html)

The whole area was ground down and templates were starting to get drawn out:
http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/Prep.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/Prep.jpg.html)

Reinforcement plates were made, and cut out.
Swiss cheese holes make for good rosette welds.
http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/Newbracketbrace.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/Newbracketbrace.jpg.html)

Testing the location of the bracket...
http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/IMG_6273.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/IMG_6273.jpg.html)

All finished: (for now)
http://i1104.photobucket.com/albums/h328/jbchill1/Track%20Bar%20repair%20May%202014/IMG_3350.jpg (http://s1104.photobucket.com/user/jbchill1/media/Track%20Bar%20repair%20May%202014/IMG_3350.jpg.html)

Brandon made short work of the project, and his work is second to none.
I cant thank him enough for the help he's provided me with his fabrication skills throughout this build. :thumbsup:

[NW99XJ]

Shortly after that I had the opportunity to DJ/MC an offroad event in SW Washington.
The Annual "Our Gang Offroad Show" is a lot of fun every year, and I'm glad to be apart of it.
http://i1104.photobucket.com/albums/h328/jbchill1/20140622_081713.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140622_081713.jpg.html)

[bluedragon436]

Looks good all repaired and ready to hit the trails again!! Why is the red XJ in the background not on here yet??? LOL

[NW99XJ]

There was a critical flaw when I first did the measuring and cutting for the track bar/panhard bar.... I made it to fit, not to what it "should be" ... the results are a track bar that is shorter than my drag link... this discrepancy in length causes some minor bump steer. Nothing I cant live with for now, but it will have to be addressed in the future if I want things to be perfect. (and I do)

Shortly after the repairs (a couple weeks or so) I had the privilege of testing out the trail my buddy Mike is building in his back yard.... and when I say yard, I mean forested acreage. It was a nice little shakedown run of the repairs.
http://i1104.photobucket.com/albums/h328/jbchill1/20140705_144857.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140705_144857.jpg.html)

Everything seemed to be ok, so I spent some time detailing the jeep for the first time since around Thanksgiving.
http://i1104.photobucket.com/albums/h328/jbchill1/20140705_202535.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140705_202535.jpg.html)

Later in June I finally got another addition to my XJ reading material.
http://i1104.photobucket.com/albums/h328/jbchill1/20140623_100810.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140623_100810.jpg.html)

I also got my very own Hidden Wounds XJ (http://www.hiddenwoundsxj.com/) T-Shirt in as well.
http://i1104.photobucket.com/albums/h328/jbchill1/20140709_130104.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140709_130104.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/20140709_130118.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140709_130118.jpg.html)

The 4th of July was right around the corner, and as usual I celebrated out nation's independence proper!
http://i1104.photobucket.com/albums/h328/jbchill1/20140704_163855.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140704_163855.jpg.html)

Not that many tubes this year... :D
http://i1104.photobucket.com/albums/h328/jbchill1/20140704_170338.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140704_170338.jpg.html)

[bluedragon436]

Looks like an awesome 4th celebration... Wish I could have been back home in SC for it so I could set of some fireworks.. Can't wait till I get back home and get back into Pyrotechnic shows.. Always a blast (literally).. I wish I had a yard I could build a nice decent trail like that one looks like it'll turn out to be..

[NW99XJ]

(gawd I'm horrible about updates lately)

so after the 4th of July celebration, it was time to gear up for the offroad show season, and some big wheeling trips.
First thing was first though, the Jeep needed some love.
Had a few things to do on the list, CB repair (been an ongoing battle - can receive, but my transmissions are garbled)...ANYWAYS, I had a million things to do, and because of me being an idiot, and thinking that the annual Jolly Jeepers weekend long wheeling event (an event I make every year) was a week later than it actually was, I had zero time to accomplish 90% of it. So a mad dash to get some work done the Friday before (the day I was supposed to leave) and on top of the list were the leaf spring eye bushings....
These Procomp 3" lift Leaf Springs have done very well over the years, but they have definitely taken some abuse, and were starting to show it.
More so than the rest was the passenger side rear eye bushing. It was toast. I could hear the bolt rattling around inside the eye as I would drive or wheel, and it obviously wasnt going to get any better without replacing it.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_113610.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_113610.jpg.html)

Since I didnt know 100% for sure if a set of Daystar or Synergy Poly bushings would fit perfectly, I decided to go with a direct replacement. My local 4Wheel Parts store steeped up and got a set drop shipped over night for free, and hooked me up. They don't ordinarily stock these, so they had to be special ordered from Procomp.
Here you can see the old vs. the new:
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_113727.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_113727.jpg.html)

Getting the old ones out was a major PITA.
Took over 5 hours of beating, hammering, cutting, pressing, and cussing to finally get it to come out. It actually had to be cut in half, then folded in on itself before it would even budge:
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_120443.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_120443.jpg.html)

But in the end I was successful. Big thanks to Wes (92WarWagon) for the assist on this.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_123802.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_123802.jpg.html)

Once out, I cleaned up the race from any burrs or sharp edges, added a quick layer of grease, and pressed in the new ones.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_124529.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_124529.jpg.html)

It was a royal PITA to get the first one in, but oddly enough, the drivers side one went MUCH smoother.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_125605.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_125605.jpg.html)

That one took only about an hour total, INCLUDING the installation of the HD Engineering Shackle Relocation Bracket! :thumbsup:

[NW99XJ]

And speaking of said brackets....
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_133449.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_133449.jpg.html)

They went in with ease, and I love how stout they are.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140718_140010.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140718_140010.jpg.html)

I do need to do some adjusting, and these brackets have plenty of room for that. The entire bracket can be flipped 180° ...there's also the various holes to adjust shackle angle, which i desperately need to do. In the above pic the jeep is not on its own weight, and not at ride height.
On the trail its a different story:
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140720_120307.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140720_120307.jpg.html)

The angle is much steeper, especially when loaded....and in fact, the shackle actually bottoms out on the bracket at a certain point thru the range of motion:
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140720_120303.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140720_120303.jpg.html)

This also produces one hell of a bouncy ride...
This was my ride into work the following week, it was so bouncy, I almost stopped for some motion sickness pills.
http://youtu.be/UAAPhiFjjWU

I haven't done it yet, but I will move the shackle one hole and see how it works. Then make further adjustments if necessary.

[NW99XJ]

That wheeling trip unfortunately was full of carnage.
I had a ton of fun, and the jeep did fantastic.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140720_114746.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140720_114746.jpg.html)

the views up here are to die for, and makes it hard to not go out as often as I can.
http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140719_112050.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140719_112050.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Jolly%20Jeepers%202014/20140719_111710.jpg (http://s1104.photobucket.com/user/jbchill1/media/Jolly%20Jeepers%202014/20140719_111710.jpg.html)

But I did manage to crack my transfer case wide open and completely grenade the DS Axle U-joint:
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140720_145836.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140720_145836.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140720_145845.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140720_145845.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140720_150014.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140720_150014.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140720_152236.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140720_152236.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140720_152257.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140720_152257.jpg.html)

When it went, it took out the ears as well... total massacre.
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_213702.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_213702.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_213710.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_213710.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_213854.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_213854.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_213647.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_213647.jpg.html)

[bluedragon436]

That's a good update.. I'd say those bushings were a bit passed needing some love!! But the XJ is looking good... Wish I had a back yard like that to wheel in!!

[4.3LXJ]

You weren't kidding about that ride Josh. A little adjustment needed for sure. I like crushers. When I get up there with the Jeep, you need to show me how to get there

[NW99XJ]

That's a good update.. I'd say those bushings were a bit passed needing some love!! But the XJ is looking good... Wish I had a back yard like that to wheel in!!
You're welcome up here any time man!


You weren't kidding about that ride Josh. A little adjustment needed for sure. I like crushers. When I get up there with the Jeep, you need to show me how to get there
I'd be happy to! :thumbsup:

[4.3LXJ]

Just might take you up on that Josh. We have family up there in Astoria. I need to find out where the locals go there. I see lots of rigs with boggers on them

[NW99XJ]

There was collateral damage when the U-joint blew.
Obviously it made a huge mess:
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_214058.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_214058.jpg.html)

But it also scalped the lower ball joint:
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_214651.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_214651.jpg.html)

Took the grease zirk with it too...
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140726_214725.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140726_214725.jpg.html)

Obviously the axle shafts could not be re-used.... So with the help of Craigslist, I procured some temporary replacements:
(Not bad for $60...) :thumbsup:
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140725_093702.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140725_093702.jpg.html)

Also thru CL i managed to find a NP242J complete with the exact same slip yoke flange I have.... So it was going to be a direct bolt in. :D
I hit it with some simple green and a scrubby brush to clean it up, gave it a good inspection once more, and did the swap. Easy peezy.
(old broken one on the right)
http://i1104.photobucket.com/albums/h328/jbchill1/Carnage%20Repair%20July%202014/20140727_133008.jpg (http://s1104.photobucket.com/user/jbchill1/media/Carnage%20Repair%20July%202014/20140727_133008.jpg.html)

I decided to take my chances and not split the case to do a full inspection.
Once installed I pulled the drain/fill plugs and started doing a visual inspection, as well as some exploration with a pic tool. All seemed fine. The chain even seemed good and tight. As it drained i noticed the fluid was dark brown, this case wasnt taken very good care of I guess....at the end of the draining, the fluid got a little sparkly. Digging around the bottom thru the drain port with my pic tool, I found the remnants of what used to be a c-clip (i think)...
All the gears that I could see looked fine, not even any stress fractures. I've since put several hundred miles on this case, and even a wheeling trip, and all seems fine. ZERO issues...... other than the speedo quitting on me a week or so later. I'll swap the sending unit from my old case, and that should take care of it!

[NW99XJ]

I needed to get these repairs done ASAP since I had a large Jeep show to DJ the following weekend. No time to do a shakedown run,
.....the test was a drive into work and back, I figured if it can make that journey and get me home,
it was good enough to transport me the hour drive south to the 3rd Annual Salem Jeepers Summer Jam with me and all my DJ equipment.
http://i1104.photobucket.com/albums/h328/jbchill1/Salem%20Jeepers%20Summer%20Jam%202014/20140802_110019.jpg (http://s1104.photobucket.com/user/jbchill1/media/Salem%20Jeepers%20Summer%20Jam%202014/20140802_110019.jpg.html)

The show was awesome, and I had a lot of fun.
This was my third year doing this event, and I'm already looking forward to next year.

Although the Jeep (and the donor T-case) proved itself fine under load and a couple hundred road miles...
I needed to see how it would handle some trail time.
So after the show, I unloaded the DJ gear, loaded up the tools, recovery, and camping gear, and made a bee line for the mountain.
http://i1104.photobucket.com/albums/h328/jbchill1/Browns%20Camp%2008-03-2014/20140803_103946.jpg (http://s1104.photobucket.com/user/jbchill1/media/Browns%20Camp%2008-03-2014/20140803_103946.jpg.html)

Three other XJ's made for a nice day out on the trails.
http://i1104.photobucket.com/albums/h328/jbchill1/Browns%20Camp%2008-03-2014/20140803_104304.jpg (http://s1104.photobucket.com/user/jbchill1/media/Browns%20Camp%2008-03-2014/20140803_104304.jpg.html)

The Jeep did very well.
Although I was babying it a little bit, I wasn't playing it safe either.
I seriously just cant get enough of the spectacular views the NW has to offer.
http://i1104.photobucket.com/albums/h328/jbchill1/Browns%20Camp%2008-03-2014/20140803_123730.jpg (http://s1104.photobucket.com/user/jbchill1/media/Browns%20Camp%2008-03-2014/20140803_123730.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Browns%20Camp%2008-03-2014/20140803_122137.jpg (http://s1104.photobucket.com/user/jbchill1/media/Browns%20Camp%2008-03-2014/20140803_122137.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Browns%20Camp%2008-03-2014/20140803_120300.jpg (http://s1104.photobucket.com/user/jbchill1/media/Browns%20Camp%2008-03-2014/20140803_120300.jpg.html)
:xj-black:

[4.3LXJ]

Glad that worked out for ya. Those last minute repairs are always the best :D

[Rocco83]

You have no idea how jealous I am of the views. That is the one bad thing I can think of in ohio. The southeast has some "hills", but we have nothing like that. You sir are lucky. Glad the tcase worked out for you and the Jeep is doing well.

[NW99XJ]

So after the last couple wheeling trips, my muffler received some carnage and now has more holes and gashes in it than a Las Vegas bunny ranch. :smiley-scared003:
I've been doing some research, and asking other peoples opinions, and I finally figured what I'm gonna do for a replacement.
http://i1104.photobucket.com/albums/h328/jbchill1/20140822_112255.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140822_112255.jpg.html)

Best price I could find LOCALLY, (that had same day pick up available) was my local NAPA Store.
At just under $40, I dont think I could go wrong.
http://i1104.photobucket.com/albums/h328/jbchill1/20140822_112220.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140822_112220.jpg.html)

So Saturday I get up and go into the garage to start the Jeep and.......
No fire.
:confused:It cranks but wont start. Awesome. :thumbsup:
I spend the rest of the day and into the evening troubleshooting everything I can...
From going thru the voltage and resistance testing procedures of various sensors and components...
To actual removal and inspection of said sensors and components.
Thru my investigation I see this:
(easy to overlook when most of what yur doing is under the hood or under the jeep)
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_150636.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_150636.jpg.html)

So after a slurry of curse words that I'm sure offended the entire neighborhood, I go online and start digging around to find an answer,
most are telling me it's just the instrument cluster, some are telling me its the PCM.
I try to hook up a code reader to find out more information.....
(hows about some "NOPE" to go along with that fail....)
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_150704.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_150704.jpg.html)

So there's a guy on my local NAXJA chapter that is parting out his late model,
I hit him up for the tranny cooler he's been saving for me, and ask if he's still got the PCM...
Sure enough, he does!...and both were acquired for a fair price.
(old and new-to-me)
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_152816.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_152816.jpg.html)

The PCM was swapped out and low and behold......
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_150636.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_150636.jpg.html)

Well at that point all I wanted to do was end this misery... :bang:
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_173516.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_173516.jpg.html)

So i did what any sane, level headed, law abiding citizen would do in a situation like this....
I tore the dash apart:
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_173410.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_173410.jpg.html)

This was of course to get at the instrument cluster and not out of sheer frustration.
I took it inside (once out of the jeep) and proceeded to clean the contacts, using a small file.
http://i1104.photobucket.com/albums/h328/jbchill1/NO%20BUS/20140824_172838.jpg (http://s1104.photobucket.com/user/jbchill1/media/NO%20BUS/20140824_172838.jpg.html)

After a good scouring on the leads (which SEEMED to be fairly clean/clear of corrosion/debris/oxidation to begin with)
....I took the instrument cluster back out to he Jeep and installed it.
"no bus"
:thumbsup:
:bang:

So at this point I was about ready to set the damn thing on fire.
I had up to this point:
-tested the TPS
-tested the Crank Position Sensor (CPS)
-tested the ASD relay
-tested the fuel pump relay
-bypassed the fuel pump relay
-bypassed the ASD relay
>>> neither of these options worked other than I DID manage to get the fuel pump to turn on <<<
-tested the CKS (CAM position Sensor / aka pick up coil / aka Distributor Ignition Pickup / aka stator / aka distributor switch plate)
-checked every fuse in the jeep (three times) - using a logic probe
-swapped the CPS for a new one (I had two spares)
-swapped the coolant temperature sending unit.
-tried to pull codes - unsuccessfully
-reset the computer (twice)
-cleaned contacts on back of inst. cluster
-blew out female connectors in dash where inst. cluster plugs in.
-swapped relays where I could
-cussed a LOT
-bled a little
-drank more than I should
-did countless hours of research online and thru my FSM (Factory Service Manual)

So thats where I'm at.... A no starting - no bus showing -bout to go to the shredder Jeep Cherokee in my garage that is starting to get on my last nerve.
.... more to come - stay tuned

[cantab27]

and that bro is THE JEEP THING ....stick at it josh gotta be something simple but ...

[Brasscatz]

First, be careful with that muffler... I got one from msmoorenburg that looked exactly like that one and it was way too long to fit under the jeep.

Now, that issue is a head scratcher... is there a loose wire(s) at the pcm connector?

[NW99XJ]

and that bro is THE JEEP THING ....stick at it josh gotta be something simple but ...
You're probably right, it's going to be something simple, and I may have already overlooked it, or it's going to be a 30 second fix, or something like that.
I just hate not being able to figure things out like this.


First, be careful with that muffler... I got one from msmoorenburg that looked exactly like that one and it was way too long to fit under the jeep.

Now, that issue is a head scratcher... is there a loose wire(s) at the pcm connector?
I've seen these things under an XJ before, the one I've got doesn't seem all that long, but i'm sure there will be some cutting and bending of new pipe will be required to get it in there.
As for the issue at hand, I checked and rechecked the plugs/harnesses going to the PCM, and all seem fine. Even pulled out the JET Chip to see if it was the culprit, and got no change.

[xj-jake]

Sorry you're having issues Josh. If you haven't seen this one maybe it will help?...

http://www.cherokeeforum.com/f2/99-xj-no-bus-no-start-195888/

[NW99XJ]

So messing around with it last night, I got the "no bus" to go away but I have no idea how.
I was able to start the Jeep after this:
http://youtu.be/zgBnPeQ4MLs?list=UUTGMY6juxbImshPlTGFB-6w

[xj-jake]

That is odd... However when I put in the new headlights I was having issues with the high beams staying on, pulled the relay for the foglamps and it fixed the problem.

[4.3LXJ]

I dunno Josh. It is a gremlin for sure. The bus thing is kind of funny. I am convinced that there is a separate chip in the instrument cluster that kind of does its own thing since there is only two wires from the ECM to it that transfer all data on oil pressure etc.

[NW99XJ]

I dunno Josh. It is a gremlin for sure. The bus thing is kind of funny. I am convinced that there is a separate chip in the instrument cluster that kind of does its own thing since there is only two wires from the ECM to it that transfer all data on oil pressure etc.
It's funny you mention that Steve... I just watched this video which explains that there IS just a single chip that controls most of the instrument cluster's display, and how to read, program, and re-write the information in it.
http://youtu.be/2sIKk8UCQyk

[4.3LXJ]

This is nice info to have. We would like to reprogram the milage on the TJ to match the 4.7 we put in

[4.3LXJ]

Just having a thought about the NOBUS situation. One twisted pair provides all the data to the bus. It comes from the ECM, also labeled bus. I realize most of the time slapping the dash will restore instruments indicating a bad connection there, but I wonder if it is sometimes a problem at the ECM also? I am not a IT guy, but it is a common problem and I wonder if we all have not found the real culprit.

[NW99XJ]

Just having a thought about the NOBUS situation. One twisted pair provides all the data to the bus. It comes from the ECM, also labeled bus. I realize most of the time slapping the dash will restore instruments indicating a bad connection there, but I wonder if it is sometimes a problem at the ECM also? I am not a IT guy, but it is a common problem and I wonder if we all have not found the real culprit.
Thanks Steve.
That has me wondering a few things now (just what i needed - thanks for THAT):p
...I wonder if those wires are multiplexed... seems like a lot of info going back and forth for just two wires, but then again, all the 5v sensors are all binary in the info that is sent. (from what I've read)
I'm also thinking that tracing down that entire length of twisted pair might be a bit daunting, so..... I wonder if I could just run my own.
Because knowing my luck..... there will be 1/4" of wire ...right in the middle, that has become a bit brittle, or oxidized, etc... and of course will be impossible to get to.
I tried swapping out the ASD relay (even though it tested fine) - my logic behind this is an intermittent "sticky" micro-switch inside... with the potential for a voltage drop on one side or the other.
Continuity tests at the relay terminals in the PDC will begin tonight before the podcast.

[4.3LXJ]

I have been into this with swapping in the V8. The wires are just regular wires on pins in the plug at the ECM. The fact there are only two wires for multiple functions was what led me to believe that there was a chip in the cluster. I was also considering a situation where one of the + power sources for the cluster isn't functioning. The one marked Batt I believe is off the ASD relay and the other is off the key. So if the one say on the key is not good, or the fuse to it under the dash, then you would get a no bus? Dunno, but have you checked that source?

[msmoorenburg]

Josh put a spare CPS in the glove box I had the same issue on a 98. See below was a fix from iant.net

Hi All: Have this jeep with a no start, no inj. pulse, no fuel pressure, no communication with P.C.M. using scan tool. Checked all fuses in the fuse panel and under the hood. Cheched for power at the coil and injectors and none was present. Checked B+ and ignition feeds to the ASD and fuel pump relays and they were good. Used a fused jumper to bypass the fuel pump and ASD relays and achieved fuel pressure, but no injector pulse or spark even though power was now present at the coil and injectors. Checked all powers and grounds at the PCM and all were good. Replaced the PCM with a reflashed, rebuilt Bluestreak unit, and still no start, with no spark, injector pulse, or fuel pressure, even on initial key cycle. Have hit a mental roadblock, and any help would be much appreciated.
the solution
Hi All: I received 18 replies to my help request with the vast majority pointing to a shorted crank sensor. I had thought about it in my original diagnosis of the no start as I've replaced a few in the past, I just could not figure how the crank sensor could affect fuel pressure, especially during initial key cycle. Well I now have been given(Merry Christmas) a generous educational gift on how Jeep sends reference voltage to the crank sensor and a short in the ref signal will disable the PCM. Wow you guys are good. One reply from Michael Cline even narrowed the syptoms down to inoperative fuel and amp guages which this vehicle also had. I knew before even heading to work that we were onto something here. Anyway the sensor was replaced, the jeep flashed right up and all is well except for the p1694 that I had mentioned was in the trans controller keeps reappearing, although with no apparent symptoms. I guess I'll have something to figure out after the holidays, any suggestions. Thanks very much to all who replied, I hope I can return the favour sometime. Mike
a shorted cps sensor can disable the ecu in a jeep aka no check engine light when key is turned on

[NW99XJ]

Good stuff right there Matt... Thanks.
I now have THREE CPS units ...the brand new one is in the jeep now, I have the OEM one from when I thought it was that a few years ago, but ended up being a grenaded rotor in the cap.... and the replacement from that.... they are all within .500 ohms from one another when tested...
and seem to fall within the normal parameters according to the FSM.
I suspect some harness/plug issues somewhere in the system. I'll be doing continuity tests for the next several days to HOPEFULLY isolate the problem.

[Carves]

I've had more issues with the crank sensors connector, on the fuel rail, than what I have - with the actual crank sensor.

..... just a thought .. ;);)

[NW99XJ]

Thanks Carves,
I've read about that same issue happening to others as well....
The wires separate from the pins inside the connector, or the pins themselves separate from the connector as well... This sort of thing is one of the issues I plan to investigate and combat once I begin the continuity tests.
I suppose one of the other issues is the female side expands, or the male side contracts, and connectivity is lost between the two mating surfaces of the pin/socket assembly of the connector pigtail and the vehicle harness plug.
(insert "hot dog down a hallway" joke here) :D

[NW99XJ]

http://www.sourballpython.com/blog/wp-content/uploads/2013/10/ItsAlive.jpg

So as you may have guessed, I HAVE FIXED THE PROBLEM!!!
After getting tons of good advice from XJTalk members, Jeepforum, and NAXJA alike, I was able to piece together a solution....
Oddly enough, the one component I was going to swap out shortly after I swapped in the donor transfer case was the culprit and cause of all these issues.
The VSS (Vehicle Speed Sensor) was to blame. Apparently it is in the same 5volt family of sensors as the Crank Position Sensor (CPS) ... o2 sensors.... and TPS (Throttle Position Sensor)...as well as all the others...
I HAD NO IDEA.
I figured, "why, during the startup sequence does the PCM need to check the condition of the VSS?" ...and "why would the SPEED of the vehicle have any bearing on the PCM to begin with"..... well i guess it does, and swapping out the VSS from the donor T-case for the one out of my old one solved my problem. One little sensor took down the entire system.
The VSS is located on the side of the transfer case, regardless of the year of XJ:
http://www.stu-offroad.com/engine/speedohealer/speedohealer-3.jpg
(picture courtesy of: www.stu-offroad.com)

It's very easily removed by a single bolt and a retaining clip.
http://www.4wdmechanix.com/images/231%20SYE%20(9).jpg
(picture courtesy of: www.4wdmechanix.com)

Pulling the VSS straight out removes it, this is not a serviceable part (for now - i may change that here very soon) ...so its just a matter of replacement.
The one I pulled out had an orange gear with the number "1" embossed on it,
and the one that came out of my old case was green, and had the number "4" embossed on it.
http://i1104.photobucket.com/albums/h328/jbchill1/20140831_150951.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140831_150951.jpg.html)

The stock one (green) is a 35 tooth, the one out of the donor case (orange) is a 36 tooth.
According to the info over at Morris 4x4 Center (http://www.jeep4x4center.com/jeep-speedometer-gears/) ...the orange one is for 33's and 4:10's.

With the two VSS units out of their respective t-cases, I merely switched the gears between the two (to keep my mental speedo-adjustment the same)
And installed the old one into the donor t-case.
http://i1104.photobucket.com/albums/h328/jbchill1/20140831_150826.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140831_150826.jpg.html)

Once done, I reset the computer, turned the key on and VOILA!
No more "no bus" ...all the gauges came to life, and the jeep fired right up.
:bacondance:

[4.3LXJ]

Glad you found that Josh. Once again, a similar case we had on the TJ where a short in the current will drain all the power out of the PCM and not allow it to function. In our case it was the positive feed to the transmission lockup solenoid.

[XJ Wheeler]

Wow, who woulda thought that sensor would be so important! Glad ya got it up and running though.

[NW99XJ]

SO.... what started this whole "no bus/ no start" adventure in the first place
was me (trying to) start the Jeep and take it to my local exhaust shop where I was going to have my old beat up,
...hole ridden Dynomax turbo muffler cut off and the new Thrush Glasspack welded on.....
I'm happy to report that the mission has been completed now! :thumbsup:

Over the last 5+ years that Dynomax has held up to an insane amount of abuse.
... but as with anything, it could only take so much.
http://i1104.photobucket.com/albums/h328/jbchill1/20140906_103408.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140906_103408.jpg.html)

The result?.... a muffler that passes, more than it muffles, which ordinarily might not be a bad thing...
But in this case, because of the shape and position of the holes, and the flappy pieces of metal over said holes....
The resulting tone from my exhaust was NOTHING short of a fart can in a blender.
http://i1104.photobucket.com/albums/h328/jbchill1/20140906_103443.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140906_103443.jpg.html)

The old Dynomax was cut out, the Thrush Glasspack was flanged, and welded in place....
http://i1104.photobucket.com/albums/h328/jbchill1/20140906_103702.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140906_103702.jpg.html)

Although I still have a header leak that is taking center stage right now, the results so far are staggering.
The tone is beautiful, and the change in back pressure has restored the torque curve to right where it needs to be.
Once I fix the header leak, I'm going to be super excited to hear what sort of sound the jeep is going to have when its all said and done.
Stay tuned!

[bluedragon436]

Glad you got her going again Josh!!.. Should of figured it'd be something completely unexpected and stupid.. Just seems like the common theme on Jeep issues..

[NW99XJ]

Looks like I forgot to post this up here....

I've had a donor throttle body laying around for some time... big thanks to my buddy Dean Murray for his generosity and donating this to the cause.
http://i1104.photobucket.com/albums/h328/jbchill1/20140710_144752_1.jpg (http://s1104.photobucket.com/user/jbchill1/media/20140710_144752_1.jpg.html)

After a few months of this thing collecting dust, it's destiny finally came to fruition....
http://i1104.photobucket.com/albums/h328/jbchill1/20141009_142812.jpg (http://s1104.photobucket.com/user/jbchill1/media/20141009_142812.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/20141009_142843.jpg (http://s1104.photobucket.com/user/jbchill1/media/20141009_142843.jpg.html)

Precision machined to 61mm with a very fine tolerance.

https://www.youtube.com/watch?v=gAoaPsb95Uw

Some of the perks to having a machine shop at your disposal... :D

[4.3LXJ]

OK, so where is the toes in the throttle body action?

[OneArmArrowSlinger]

Awesome machine work!

[NW99XJ]

Someone recently asked me:

What else do you have in the works?

Ohhhh... Lets see....

APN Header has to come off and get welded.
CB is going to get overhauled.
I have a bunch of LED Lights to fab brackets for and install.
Front bumper needs to get finished (sides)
I also have some rock lights to put in.
I built a new sunroof control module from scratch, and that needs to get installed.. along with a new switch panel if i cant get the old one to play well with the new module.
I have a set of new (to me) Bilsteins that need to go on.
There's the frame stiffeners of course.
I also have an AEV style T-case skid plat to put in.
The Transfer case needs to be rebuilt (donor one has worn shift forks - so i'll just swap the guts from the one I busted open last summer)
Dual battery set up needs to get figured out, which means...
Cowell Intake.
Mud flaps.
New axle shafts for the front.
I still need to bore out the throttle body spacer i have to match the bored throttle body that still needs to be installed.
Tranny flush.

Oh ...and I need to procure or build a cross member for these:
(which i have had sitting around for WAY too long)
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_2008-1.jpg (http://s1104.photobucket.com/user/jbchill1/media/IMG_2008-1.jpg.html)

Thats all.... lol ....Just a small list of things to do. :shhh:
A couple things I would LIKE to do are:
WJ Knuckle swap
- which would mean i would need to completely re-do my steering. (ugh)
New leaf springs for the rear, OR.. go with a coil set up... but that's WAY down the road.
I Also wouldn't mind figuring out a rear tire carrier for the rear bumper, and while i'm at it, I was going to figure out a way to tie in some rear quarter guards as well.
And something i have been toying around with doing is plating the bottom of my WP Rock Barz with a strip of 3/16" steel to not only act as reinforcement, but to also give the sliders some extra meat to drag over the rocks.
I could prob get away with .125... but it will come down to price and availability of bar stick whenever i get around to doing something about it.
And one of these days I REALLY would like to do some tube fenders....that may happen sooner than later, but we'll see.

I have had all winter to mess around with this stuff, but it seemed like since November, I have worked on other peoples rigs more than my own. Motivation has been lacking quite a bit lately as well. I just need to get my butt in gear and start knocking some of this out.

[4.3LXJ]

Nice list, better get going. It is wheeling season you know

[OneArmArrowSlinger]

Nice! Which Bilsteins you go with?

[NW99XJ]

Nice! Which Bilsteins you go with?
Just the 5100 series.
But they're a massive upgrade from the old Rough Country shocks that are on there now.
I thought i had a pic to share, but I guess i dont...

[OneArmArrowSlinger]

Sweet. I just helped one of my buddies just put those on his XJ, can't wait to see how they perform for him this weekend.

[NW99XJ]

One of my local parts stores is getting "boughten" out by a competitor...
So virtually everything in the store that is no longer going to be kept in stock is being liquidated at 30%-70% off.... most things falling in the 50% range.
So i picked up several items of shop supplies, and few bottles of this fluid or that.
I also got a couple new tools, the least of which is a decent set of C-clip pliers. The HF ones I HAD been using are completely worthless. Not much good for anything but hobby work. I grabbed a few other things too, but needless to say, this is all in the hopes that I will get my arse in gear and do something with this thing.
More to come soon.... i promise. :P

[prerunner1982]

Hopefully it doesn't take you as long to get back to Jeep building as it did for you to get around to getting your ham license. :D;)

[NC_Xplorer]

JULY 2012:
Well that brings you all up to speed, thats my build so far.
Here's the latest:
Two wheeling trips in the last two weeks, and a little photo shoot with my girl as well....
Enjoy:
http://img6.imageshack.us/img6/959/img1565qi.jpg (http://imageshack.us/photo/my-images/6/img1565qi.jpg/)

http://img193.imageshack.us/img193/2457/carwashbehbeh023.jpg (http://imageshack.us/photo/my-images/193/carwashbehbeh023.jpg/)

http://img651.imageshack.us/img651/8745/carwashbehbeh019.jpg (http://imageshack.us/photo/my-images/651/carwashbehbeh019.jpg/)

http://img440.imageshack.us/img440/7444/carwashbehbeh020.jpg (http://imageshack.us/photo/my-images/440/carwashbehbeh020.jpg/)

http://img31.imageshack.us/img31/8572/carwashbehbeh036.jpg (http://imageshack.us/photo/my-images/31/carwashbehbeh036.jpg/)
Hubba hubba!

Sent from my SAMSUNG-SGH-I337 using Tapatalk

[NW99XJ]

I am a lucky man indeed.

[Brasscatz]

I am a lucky man indeed.

Until we find out that's your sister.... and your subconscious is hiding your true significant other :D :poke:

[xj-jake]

No wonder he never comes around any more!

[NC_Xplorer]

Wow! Just finished reading the entire build thread and have learned so much about my 98 in regards to parts I need to replace and things to look for when Jeep stuff happens. My XJ had 205k on the clock when I bought it so I know it is in desperate need of some TLC. Keep up the the great work on the build thread. Looking forward to seeing your XJ evolve more as time goes on!

Sent from my SAMSUNG-SGH-I337 using Tapatalk

[NW99XJ]

Thanks!... that was my intent all along,
As long as at least ONE person gets some useful information out of all this, then i'm happy.
Feel free to hit me up with any questions you may have, or if you need any clarification on something, post up a question!

[abebehrmann]

Hubba hubba!

Sent from my SAMSUNG-SGH-I337 using Tapatalk

Those shoes sure don't look conducive to off roading and vehicle recovery, but I'm not complaining!

[NW99XJ]

Thanks!... that was my intent all along,
As long as at least ONE person gets some useful information out of all this, then i'm happy.
Feel free to hit me up with any questions you may have, or if you need any clarification on something, post up a question!

[NW99XJ]

Hopefully it doesn't take you as long to get back to Jeep building as it did for you to get around to getting your ham license. :D;)

AS it turns out.... it didnt.
...but close. ;)

It was long overdue to fix my leaky header....thats right, the one I got clear back in '12...

New Exhaust Manifold: (Roughly $73 - Shipped)
http://www.ebay.com/itm/New-Exhaust-Manifold-Jeep-Wrangler-99-98-97-95-94-93-92-91-Cherokee-Car-4883385-/250913149079?pt=Motors_Car_Truck_Parts_Accessories&fits=Year%3A1999|Make%3AJeep|Model%3ACherokee&vxp=mtr&hash=item3a6b96d097
http://i1104.photobucket.com/albums/h328/jbchill1/KGrHqRpE8Vh2ttUBPNeSP7rMQ60_12.jpg


I am no stranger to the turmoil that is header removal.... yes it is true, that I would rather go thru a root canal than have to do this procedure...at least that way, its's someone else doing all the work.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150822_194720.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150822_194720.jpg.html)

I was in no hurry, I didn't have many "F's" to give, so I was tinkering throughout the day, and in-between commercials... BUT, progress was made.
Once I was at this point the whole "WJ PS Pump Swap" was really coming to mind.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150822_211226.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150822_211226.jpg.html)

The injector rail came out with ease, and it was set aside to be cleaned.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150822_212351.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150822_212351.jpg.html)

After that, it was just a matter of the blots in the block holding the two manifolds on, and off they came:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_110700.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_110700.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111126.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111126.jpg.html)

Here it is... it's first time being out in the open since 2012.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111202.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111202.jpg.html)

Well after a couple rounds of motor mounts, this thing just couldnt take the abuse.....but I found it more of a flaw (or poor judgement) in manufacturing, than my motor flopping around. I'll explain:
The OEM exhaust manifold is long hailed as a poor design, weak in construction, and breathes about as well as a 95 yr old chain smoker with emphysema. So I THOUGHT i had found a suitable replacement...
More Free flowing, better design, incorporated movement/thermal expansion joints.... and (quote from the seller)...
"Cast iron construction; Tubular design; A high quality, direct fit OE replacement exhaust manifold; Made with durable, heat controlling materials for long-lasting life"

[NW99XJ]

So.... after less than three years, (and lets face it, the last two plus years the Jeep has been retired from daily driver status)...
THIS is what "durable/long lasting" looks like:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111234.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111234.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111243.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111243.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111257.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111257.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111322.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111322.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111322.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111322.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111343.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111343.jpg.html)

Thats SIX ...count 'em... SIX FRICKIN LEAKS! .... everyone I've show these to, say those are shotty welds.
I would have to agree, a couple of these look like I could simply take a pair of pliers and just pull the weld right out.
In the words of a famous Wayans brother... "Homie dont play that!"

[Carves]

So.... after less than three years, (and lets face it, the last two plus years the Jeep has been retired from daily driver status)... THIS is what "durable/long lasting" looks like:

Looks like they used sikaflex instead of welding it .. :confused: .. ;);)

XJ manifolds do get way too hot,

... But it would be interesting to see some statistics of the ecology pros and cons of fuel emissions versus manufacturing pollution from making all the extra vehicle spare parts - to replace items with emission friendly, shorter life spans .. :rolleyes:

[NW99XJ]

With every intent of welding the leaks up, I prepped it AND my old OEM header with the wire wheel treatment.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_120555.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_120555.jpg.html)

Thats right.... I STILL held on to the ol girl..dont look too bad for her age either, just onnnne little crack:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_120541.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_120541.jpg.html)

I kept it for all these years... "just in case" I could find a use for it. :crazy:
http://cdn.funkyspacemonkey.com/wp-content/uploads/2012/06/iXoost-iPhone-audio-system-9-FSMdotCOM.jpg

[NW99XJ]

Just take a closer look at the "integrity" of the welds on this thing:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_141820.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_141820.jpg.html)

Once cleaned up and prepped, I took it over to my buddy Brandon, since his welding skills (and equipment) are far greater than mine. Over at hios place there was a Cherokee "work party" happening,
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_133433.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_133433.jpg.html)

I Brandon (thanks for the assist on this man - you're the best) to make a few NEW "cracks" in my old header using the band saw.... so that he could use those to practice on, to get a good baseline measurement to set his Millermatic 250 to.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_134739.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_134739.jpg.html)

What I found out about this header in the moments that follwed...and why I think it's not as good in some areas as the OEM is this....
The pipes leading from the flange, off of each cylinder, are of a gauge at least TWICE as thick as the collector pipes, maybe more. Needless to say, welding these things up proved to be a real challenge, with the collector pipes being nearly tinfoil.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_141456.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_141456.jpg.html)

It was very difficult to keep the welder from blowing thru the MUCH thinner material, while still getting good penetration on the thicker material.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_141449.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_141449.jpg.html)

[NW99XJ]

Brandon set to task, and made short work of it all:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_141359.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_141359.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_143422.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_143422.jpg.html)

The results aren't pretty, but this ain't a beauty contest.
The header is sealed, and I now also have my old stocker sealed up now and on standby.... "just in case"
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_144412.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_144412.jpg.html)

[tinythexj]

It's been at least a year and a half since I've installed my replacement but I don't remember my welds looking that bad.

[NW99XJ]

Some of you may have heard on a recent episode of The Jeep Talk Show, that my Jeep gave a slight fit of overheating on my way back from the Salem Jeepers Summer Jam.
I MAY have found part of the reason:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/20150823_111136.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/20150823_111136.jpg.html)

This is a real :bang:
Basically I have to pull some magic out of my A$$ and come up with one hell of an ingenious repair, or I'm looking at replacing the entire radiator because of one little nipple.

[4.3LXJ]

Brass,aluminum or plastic?

[NW99XJ]

My plan.... thus far...is this:
Cut/shave/grind/file the remaining (plastic) nipple off to this point:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/radcapmod.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/radcapmod.jpg.html)

Then thread the remaining material to accept a threaded barbed hose fitting.
Something like one of these:
http://www.nitrousexpress.com/prod_images/xlarge/16100.jpg

[NW99XJ]

The other things I have on my mind now that half the engine is torn apart....
Valve Job.... since I need to replace the valve cover gasket anyways... "while you're in there"
...which is why I had the WJ pump swap on my mind.
Other things include a block painting...needs to be cleaned up real bad anyways,
And motor mounts..... yes again.... this time I'm going poly like I should have done last time. GRRRR!

[4.3LXJ]

Don't you just love it when one project lead to another. Got one of those coming up too

[ZachXJ1993]

See on my jeep all I wanted to do was put on 31" tires...one thing lead to another and now I have parts for 37's on tons and 350 swap. Careful Josh soon that manifold job will turn into a chop top and a truggy cage.....

Sent from my XT1080 using Tapatalk

[xj-jake]

Looks like that job was long overdue. But you are right as long as you're in there take care of things the right way the first time. In the words of my dad, "Do it right, don't do it twice."

[NW99XJ]

See on my jeep all I wanted to do was put on 31" tires...one thing lead to another and now I have parts for 37's on tons and 350 swap. Careful Josh soon that manifold job will turn into a chop top and a truggy cage.....

Thats how it all started for me too!
At least this thing is just a toy now, so I can get away with making plans like that....the problem I have is execution and cash flow. (not necessarily in that order)

[Mudderoy]

The other things I have on my mind now that half the engine is torn apart....
Valve Job.... since I need to replace the valve cover gasket anyways... "while you're in there"
...which is why I had the WJ pump swap on my mind.
Other things include a block painting...needs to be cleaned up real bad anyways,
And motor mounts..... yes again.... this time I'm going poly like I should have done last time. GRRRR!

Cough, brown dog, cough...

8119

[denverd1]

post up the name of your header vendor or ebay seller please. Don't want to make the same mistake.

also for the hose that goes to rad filler. I think you're :out: trying thread that. I'd put a piece of hose over it and clamp it. Maybe run new hose to the res, or put a coupling in there to the current hose.

[NW99XJ]

post up the name of your header vendor or ebay seller please. Don't want to make the same mistake.

also for the hose that goes to rad filler. I think you're :out: trying thread that. I'd put a piece of hose over it and clamp it. Maybe run new hose to the res, or put a coupling in there to the current hose.
The only problem with putting a hose over then and clamping it is the clearance between where the top of the hose & clamp would be and the bottom of the radiator cap.
It;s like "right there" ...meaning I'm not sure I'll have the clearance to make everything seat right.
The other thing is that now that I go back and check it out... that nipple is like wet cardboard.
I can literally flake it off with my thumb nail... so tapping it may be out of the question too.
However with THAT ...the inside diameter of the remaining nipple is more structurally sound than the outer diameter.
Making it a more feasible option. Worst case scenario, I tap and it doesn't work/strips out.... I can come up with a plan B.
Even if that mean drilling the side of that neck out so that I can shove the end of the hose in it and epoxy it closed.

As far as where the header came from:
(top of the thread)
http://www.xjtalk.com/showpost.php?p=212904&postcount=311

[NW99XJ]

Hmmmm......
"While i'm in there".....

http://jeep.blackonyx.net/forum/Hesco2xtrouble.jpg

[4.3LXJ]

That looks like fun. Now why didn't I think of welding that on there?

[NW99XJ]

More work was done over the weekend....
The Valve Cover Gasket was in need of replacement, luckily for me, i was swimming in FelPro at this point.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_172925.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_172925.jpg.html)

Since basically everything was torn apart already, everything was relatively easy to get to and remove.
First up was the PCV/CCV elbows and grommets... which were prob ok to leave alone for a while still,
... but there was evidence of a little blow-by, so i opted to replace them anyways. One came out easy.... the other, not so much.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140413.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140413.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140510.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140510.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140717.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140717.jpg.html)

The wire harness is next. This housed in a fixed loom which is pressed onto a couple of the valve cover studs.
Best way to get this off is with a small pry tool.
A cats claw or pry-bar would also prob work just fine.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140548.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140548.jpg.html)

Just get underneath the flange at each stud with the end of the pry tool,
and apply some downward pressure...
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140606.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140606.jpg.html)

Doing this at each point, will ensure the loom comes off evenly and intact.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140636.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140636.jpg.html)

Then it was time to get to the hardware. All the bolts/studs are 7/16.
I went around and broke everything loose, before I pulle dthe whole thing off.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140656.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140656.jpg.html)

[NW99XJ]

Once you get around to the other side, there is more hardware that will need to be removed, before you can get to the bolts.
The heater hose retainer clip is one such piece, it too slides off the stud with ease.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140821.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140821.jpg.html)

Underneath that is the spark plug wire retainer, this is bolted down, so dont go and start prying on it.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140843.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_140843.jpg.html)

The rear most bolts are a little tricky to get to, I would highly recommend picking up a set of U-joints for your sockets.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144028.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144028.jpg.html)

Something I learned from an old engine builder many years ago, is that if you want to make things easy on yourself in the future... keep track of your bolts, and where they go. The best way to do this I found, is to use a piece of cardboard, a sharpie, and a #2 Phillips screwdriver (to punch holes in said cardboard.)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144318.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144318.jpg.html)

The #2 Phillips, is just the right size for 7/16 bolts.
You can literally screw your bolts right into it...
As you can see this keeps them in order, no matter what you do with the cardboard. (your welcome for the tip) :thumbsup:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144400.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144400.jpg.html)

Once all the bolts were out, a swift hit with the palm of the hand, and the valve cover separated, and was removed easily.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144544.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144544.jpg.html)

Ta-Da!
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144712.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144712.jpg.html)

At this point the thoughts of "hey...yur only another 20 or so bolts and a cherry picker away from having this engine out of the vehicle."
:out:

That's when i knew it was time to move forward before anymore insanity like that reared its head.

[bluedragon436]

Ta-Da!
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144712.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_144712.jpg.html)

At this point the thoughts of "hey...yur only another 20 or so bolts and a cherry picker away from having this engine out of the vehicle."
:out:

That's when i knew it was time to move forward before anymore insanity like that reared its head.


Hope my valvetrain looks that good when I pull my valve cover for a new gasket...

[NW99XJ]

Next up was some detail work....
The surfaces that ANY gasket are to be in contact with should be free and clear of any grease, dirt, debris,
...or anything that could otherwise compromise the integrity of the seal or the gasket itself.
This surface was definitely in need of some attention before the new gasket could be placed.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150045.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150045.jpg.html)

Grease, grime, gunk, sludge, oil, and dust... all makes for a lovely coating of funk.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150059.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150059.jpg.html)

First I go at it with a rag, wiping away the debris, and all the "main stuff" that more easily dealt with in this manner.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150112.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150112.jpg.html)

Once thats out of the way, we can start to see some shiny metal.
(this is a good thing)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150551.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_150551.jpg.html)

To make the surface easier to get to, and for ease in placing the new gasket later, I opted to remove my "firewall-to-block" ground strap. (or in my case, ground cable)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_151120.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_151120.jpg.html)

At this point i was really putting in some work.
The last thing you want is to get everything buttoned up and fired up,
...and discover you have a small leak that could have easily been avoided with some attention to detail....
So I went all in.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_155926.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_155926.jpg.html)

Ok back to the head.
Once the initial wipe-down was complete, I went over the gasket surface once more with some Scotchbrite.
This time really getting every last little bit of anything left over, off for good. I'd say that looks a lot better....
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_210624.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_210624.jpg.html)

With the gasket surface all prepped, it was just about time for the gasket to placed.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182457.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182457.jpg.html)

Anytime I do any serious work on the Jeep I am always inspecting everything as I work.
Paying close attention to replaceable/serviceable parts, and the things I know typically wear out over time.
Here i found a small crack in one of the heater hoses.
Not a big deal, I'll prob just cut it at the crack, and call it good.
A replacement will likely get ordered (just in case)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_161405.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150829_161405.jpg.html)

[NW99XJ]

Some of the replacement valve cover gaskets out there do not come with new inserts.
I opted to get the one that does. It's a little more, but worth it in the long run.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_173922.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_173922.jpg.html)

With the valve cover placed into its new home, it was time to shift the attention to the valve cover itself.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_210657.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_210657.jpg.html)

Over the period of time that it was leaking, there was a considerable amount of dust and gunk that had built up after combining with the leaked oil. This sludge was everywhere. I could draw my finger across the flange, and come up with a good chunk of the lovely tar like goo.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174947.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174947.jpg.html)

In order to really clean things up PROPERLY (and i cant think of a single reason why you wouldn't,)
...You'll need to get all of the inserts out of the valve cover.
They come in two pieces, the metal insert, and a plastic retainer.
The metal part needs to be saved, but the plastic part will get replaced with the new ones from the kit.
The easiest way to remove them? ...a small pry bar.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174550.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174550.jpg.html)

Trust me, dont bother trying to clean thing sup too much till you have these out.
With a little pressure from the mini pry bar, they pop right out:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174559.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174559.jpg.html)

Here's a close up of the insert/clip assembly when out.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174432.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_174432.jpg.html)

With all the inserts out, you can now do a good cleaning of the cover.
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182522.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182522.jpg.html)

[NW99XJ]

With the cover cleaned and set aside, it was time to address the inserts.
The old retaining clips needed to be separated from the metal inserts.
At first I used a small thin screw driver, holding one in one hand and working the screwdriver with the other.

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182612.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182612.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182651.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_182651.jpg.html)

This proved to be a mind numbing, time consuming, hand cramping nightmare.
So I decided to use my noodle for a change, and came up with a much better, and faster way of doing this.
A larger flat head, and our old friend the stubby #2 Phillips (which has a perfect diameter for the inside of the metal inserts.)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183836.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183836.jpg.html)

That worked out MUCH better. And I had them all separated within a couple minutes. Once Out... I thought they could use a little cleaning up.
And a simple wipe-down wasn't going to cut it. Not with 230+ thousand miles of gunk cooked on em. So I tried a wire wheel treatment on one, and.....
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183210.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183210.jpg.html)

Looks pretty good to me!
(wiped down on Left - wire wheeled on Right)
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_185307.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_185307.jpg.html)

Only problem is I dont have a bench grinder with a wire wheel....
So i did what any drill-owning-vice-having Jeeper would do... I improvised. :D
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183156.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_183156.jpg.html)

[NW99XJ]

The only left to do was install the newly cleaned inserts with their new clips back into the valve cover.
Got a VERY NICE surprise, and even had the girlfriend come help out. :thumbsup:
http://i1104.photobucket.com/albums/h328/jbchill1/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_211051.jpg (http://s1104.photobucket.com/user/jbchill1/media/Header%20Repair%20Aug%202015/Valve%20Cover%20Replacement%20Aug%202015/20150830_211051.jpg.html)

[xj-jake]

Nicely done Josh! That's a fairly simple project to tackle and lets face it, it probably gets over looked quite often. The valve cover inserts must be on the new style motors only? I don't recall seeing them on my '88.

[NW99XJ]

While sitting at my desk today (08/31/2015)
I was presented with what I THOUGHT I was going to be able to take home on Friday.
My now bored and matched throttle body and spacer!
:woot:
http://i1104.photobucket.com/albums/h328/jbchill1/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115135.jpg (http://s1104.photobucket.com/user/jbchill1/media/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115135.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115158.jpg (http://s1104.photobucket.com/user/jbchill1/media/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115158.jpg.html)

http://i1104.photobucket.com/albums/h328/jbchill1/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115223.jpg (http://s1104.photobucket.com/user/jbchill1/media/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115223.jpg.html)

Doesn't get any better than that!
http://i1104.photobucket.com/albums/h328/jbchill1/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115344.jpg (http://s1104.photobucket.com/user/jbchill1/media/Throttle%20Body%20and%20Spacer%20-%20Bored%20%20-%20Aug%202015/20150831_115344.jpg.html)