X/ZJ's - What to look for?

[Kunker]

Looks like I might be in the market for a beater XJ or ZJ...anyone have any advice on what to look out for on these trucks? So far the list is:

- rust on rockers
- wiring through doors (PW, PDL, etc)
- 4.0 exhaust manifold

Anything else I should keep an eye peeled for?

 

[dwcjwerfner]

What I have seen with ZJ's is that the rust can get really nasty around the rear axle control arm mounts, they are very thin brackets (read thick sheet metal), Cory ripped his '93 right off the 'frame' at Spring Fever and some of other one's I have seen since then are quite rough in the area due to poor design causing dirt and salt to accumulate there.

 

[szabotage]

earlier XJ models, not sure on the year, came with a D44 rear. came as a tow package option.

 

[Mini-T]

The XJ D44 is extremely rare. Offered only from 87-89 on trucks with the towing package.

 

[Root Moose]

This is XJ specific...

ChryCo 8.25 29 spline is close to the same strength as a D44 but can only go as low as 4.56:1.

The 27 spline is "easy" to upgrade to 29 spline. Swap the spider gears and axles, otherwise everything else is bolt together. The transition to 29 spline was around 1995 IIRC (verify!).

Just avoid the Dana 35 and all is well.

From 1992 up all front axles should be non-disconnect (IIRC).

What's your budget to source the victim, err, XJ? Different years had different perks and downfalls. Personally, I think the first run with the GM V6 should be avoided, the next three runs after that (RENIX, ChryCo HO, new style) are all suitable. If it were me pick the newest one you can afford.

On the ZJ the 42RE was supposedly weak but by now those have probably been weeded out and/or rebuilt. I'd take a 4.0 over the 5.2 just for the fuel economy but it depends on what you have in mind to do with the Jeep. Too bad they never but the 4.7 V8 in the ZJ.

Duty calls, will add more later.

 

[Root Moose]

For XJs the cut over from the old body and interior to the new is 1996. 97+ is the new stuff.

99 is the last year with a high pinion front axle.

2000 is the first year with distributorless ignition. FWIW, this sounds "scary" but the cost to replace the wires and cap on the old system versus the more reliable new system that is less prone to water issues is a wash. Unless you run cheap Chinese junk wires of course.

~2000-2001 use the 0331 casting for the cylinder head (coincides with ditributorless ignition - boss cast for mounting IIRC). They have a reputation for cracking at around cylinder #3. I've got 205,000 kms on mine and haven't had an issue yet. It happens but not a big deal to retrofit a 7120 or 0630 casting if you have to. They don't fail catastrophically. Anecdotally I hear the failure rate is in the low single digits as a percentage.

I'm not 100% certain but 1989 was the last year for the RENIX style fuel injection (and 90 first year of ChryCo HO setup - need to verify the exact year). The RENIX system is old but don't let that scare you away from it. Very reliable and "tunable" if you go the stroker route (has knock sensor). The old RENIX blocks are supposed to have a higher nickel content as well so in theory should be capable of higher miles between rebuilds.

For the ZJ there was a mild restyle for 96. The front grille was updated (droops into the bumper instead of being completely straight horizontally) and the interior was mildly restyled. Probably some other stuff I'm forgetting too. Something about the QuadraTrac (NV249) getting a better low range engagement method or something.

If you can, get SelectTrac on the ZJ. The viscous couples on the QuadraDrive setups wear out and are expensive to fix. You can retrofit a SelectTrac (NV242) or CommandTrac (NV231) into a ZJ if you want to go that route.

There's three engines in the ZJ, 4.0, 5.2 and 5.9. 5.9s are out there but are normally setup with Qtrac. It's a big thirsty engine - it takes premium gasoline. I think it is too much engine for a wheeling rig the size of a ZJ but people differ on that. The 5.2 is ok but in that vintage Jeep I'd look hard at the 4.0 for the fuel economy numbers. You'll be hard pressed to get the posted mpg out of the 5.2 IMO.

The Dana 44s in the ZJ have an aluminum housing. If you get one plan on retrofitting a proper D44 or a Ford 8.8 at some point in the future.

Depending on how you intend to use this Jeep have a look at the WJ too. I've been warming up to them - will likely be my next Jeep unless I get forced into a 7 passenger TLC or something.

HTH

 

[Cochise]

Here's a good page for XJ specs, including what year various axles/trannies were used:

http://jeephorizons.com/tech/xjstockspecs.html

Added in-line for keepsakes.

Jeep Horizons

Author: ThePhantum

All XJs were built as a "Unibody"…meaning that the body and frame rails not just tied together, they are one piece, as opposed to a frame with the body mounted to it (like Wranglers are). All XJ's have solid axles in the front and in the rear. The suspension consists of coil springs up front and leaf springs in the rear. All XJ's came with disc brakes in the front and drums in the rear.

Dimensions
(There may be small differences, dependent upon trim level and/or optional equipment)

Wheelbase = 101.4"
Overall length = 165.3" - 168.8"
Overall width = 67.9" - 70.5"
Track = 58"
Height = 64" (with roof rack 66.8")
Ground clearance from differentials = 7.3" (Upcountry = 8.3")
Approach angle = 37.6? - 38?
Departure angle = 31? - 32.1?
Breakover angle = 21? - 21.9?
Curb weight 2wd = 2,891 lbs - 2,993 lbs
Curb weight 4wd = 3,057 lbs - 3,386 lbs
Cargo capacity = 71.0 cu ft.

Body
The body comes in both 2-door and 4-door styles with a rear hatch (liftgate).

In 94 side-impact beams were added to the doors and roof was strengthened. The 3rd brakelight was added to the top of the liftgate as well.

In 96 the body structure was strengthened some...it was not noticeable in overall appearance.

In 97 the body and interior were redesigned. Most noticeably it gave the body smoother lines by changing the bumpers, flares, and moldings. The front fender was trimmed just below the headlights and replaced with plastic bumper endcaps that wrap around to the wheel well. The windshield washer bottle was relocated to the inside of the drivers side front fender and the liftgate was also changed from fiberglass to sheet metal.

Engines
2.5L I4 carburated - 105 hp @ 5000 rpm, 132 ft lb torque @ 2800 rpm - used in 84-85 models

2.5L I4 TBI (fuel injected) - 117 hp @ 5000 rpm, 135 ftlb @ 3500 rpm - used in 86 and updated in 87-90 to 121hp

2.5L I4 MPI (multi-port injection) - 130 hp @ 5250 rpm, 139 ft lb @ 3250 rpm - used in 91-00

GM 2.8L V6 - 115 hp @ 4800 rpm, 145 ft lb @ 2400 rpm - used in 84-86

Renault 2.1L 4cyl. Turbo Diesel - 85 hp @ 3750 rpm, 132 ft lb @ 2750 rpm - used in 85-87

Italian VM 2.5L Turbo Diesel - 140 hp, 236 ft lb torque - used in overseas XJs

4.0L I6 EFI "Power Tech" - 177 hp @ 4750 rpm, 220 ft lb @ 4000 rpm - used 87-90

4.0L I6 MPI "Power Tech HO" (High Output) - 190 hp @ 4750 rpm, 220 ft lb @ 4,000 rpm - used in 91-95 and updated in 96-01 to 225 ft lb torque @ 3000 rpm (00-01 models use a distributorless ignition system)

Transmissions
Manual Transmissions

AX4 - 4 speed manual - manufactured by Aisin - used 84-86 with 2.5L I4 and 2.8L V6 engines
T4 & T5 - 4 & 5 speed manual - manufactured by Borg Warner - used 84-86 with 2.5L I4 and 2.8L V6 engines
BA10/5 - 5 speed manual - manufactured by Peugot - used only up to 89
AX5 - 5 speed manual - manufactured by Aisin - used with 2.8L V6 and 87+ with 2.5L I4
AX15 - 5 speed manual - manufactured by Aisin - used with 4.0L I6 engines
NV3550 - 5 speed manual - manufactured by New Venture - used in 00-01 in SE models with 4.0L I6 engines

Automatic Transmissions

Torqueflight 904 - 3 speed automatic - used 84-86 with 2.8L V6 and 2.5L I4 engines
30RH - 3 speed automatic - used with 2.5L I4 engine 94?-00
AW4 - 4 speed automatic, electronically controlled - manufactured by Aisin - used from 87-01 (87-91 models include a Power/Comfort button that adjusts the shift points)

Transfer Cases
All the transfer cases used are all chain driven with aluminum housings. T-cases were designated either NP or NV. They are essentially the same t-case...just a different "brand name" (NP was used for the purposes of this list:

NP ="New Process"
NV = "New Venture"

NP207 - "Command-Trac" part-time only - 2.61:1 ratio low range - used 84-87

NP231 - "Command-Trac" part-time only - 2.72:1 ratio low range - shift pattern 2H - 4H - N - 4L - used 87-01

NP228/NP229 - "Selec-Trac" - 4Hi(full-time) - N - 4Lo (part-time) - used 84-87

NP242 - "Selec-Trac" part-time OR full-time - 2.72:1 ratio low range - shift pattern 2wd - 4part-time - 4full-time - N - 4LO - used 87-01

Driveshafts
Front Driveshaft - On 84-87 XJs (NP207 t-case) the front shaft is a "GKN" style shaft. On 87-01 XJs (NP231/242 t-case) the front is a "double cardan" two-piece driveshaft with a CV joint at the transfer case end.

Rear Driveshaft - The rear is a one-piece shaft with standard u-joints at both ends. The slip yoke is located on the output shaft of the transfer case. On 84-95 models, the yoke slides in and out of the transfer case and is lubricated by the ATF fluid internally. On 96-01 due to a design change, the slip yoke is external (does not slide in and out of the transfer case). This slip yoke is covered with a rubber boot.

Axles
Front Axles

Dana 30 high pinion - reverse cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear - used 84-99 (some axles through 91 are vacuum disconnect, 92+ are non-disconnect, 89-95 with ABS have 5-297x u-joints, all 95+ have 5-297x u-joints, all others have 5-260x u-joints)

Dana 30 low pinion - standard cut - 27 spline, 1.16" diameter shafts, 7.13" ring gear, 5-297x u-joints - used 00-01

Rear Axles

Dana 35 non c-clip - 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube - used 84-89

Dana 35 c-clip - 27 spline, 1.18" diameter shafts, 7.58" ring gear, 2.62" axle tube - used 90-01

Chrysler 8.25 - 27 spline, 1.17" diameter shafts, 8.25" ring gear, 3" axle tube - used 91-96

Chrysler 8.25 - 29 spline, 1.21" diameter shafts, 8.25" ring gear, 3" axle tube - used 97-01

Dana 44 non c-clip - 30 spline, 1.31" diameter shafts, 8.5" ring gear, 2.75" axle tube - used 87-89 on some (not all) XJs equipped with towing package.

Note: Dana 35 axles sometimes referred to as Dana 35C - The "C" does not stand for c-clip. It stands for "custom" meaning it came from Dana unfinished.

Note: 8.25 axles - none of these axles were used on XJ's with ABS brakes. If you have ABS, you have the Dana 35. Without ABS you could have either axle. 8.25 axles are c-clip.

Gearing
3.07 - used with 4.0L engine / manual transmission
3.31 - only available on older (pre87?) 2 door XJs with "Fuel Economy" package
3.55 - used with 4.0L engine / automatic transmission
3.73 - found in some XJs with the towing package
4.10 - used with 2.5L engine usually, and older XJs with the "Off-Highway Vehicle" package.

Cooling Systems
Open style - any normal cooling system used today. Opposite of closed style described below.

Closed style - has no radiator cap and utilizes a pressure bottle. This style cooling system was used in 87-90 XJs.

Airbags
Drivers side airbag (mechanical) was added in 1995.
Passenger side airbag was added in 1997. Airbags changed from mechanical to electronic in this year also.
Production Numbers
Number of XJ's built in given year:

1984 - 93,326
1985 - 120,328
1986 - 107,225
1987 - 139,295
1988 - 187,136
1989 - 207,216
1990 - 151,230
1991 - 151,578
1992 - 137,826
1993 - 144,961
1994 - 123,391
1995 - 120,234
1996 - 286,463
1997 - 258,958
1998 - 182,845
1999 - 186,116
2000 - 165,590
2001 - 120,454

Total = 2,884,172

Trim Levels
84 - Base, Wagoneer, Pioneer, Chief
85 - Base, Wagoneer, Pioneer, Chief, Laredo
86 - Base, Wagoneer, Pioneer, Chief, Laredo
87 - Base, Wagoneer, Pioneer, Chief, Laredo, Limited
88 - Base, Wagoneer, Pioneer, Chief, Laredo, Limited, Sport
89 - Base, Wagoneer, Pioneer, Chief, Laredo, Limited, Sport
90 - Base, Wagoneer, Pioneer, Chief, Laredo, Limited, Sport
91 - Base, Briarwood, Chief, Laredo, Limited, Sport
92 - Base, Briarwood, Chief, Laredo, Limited, Sport
93 - Base, Sport, Country
94 - SE, Sport, Country
95 - SE, Sport, Country
96 - SE, Sport, Country, Classic
97 - SE, Sport, Country
98 - SE, Sport, Classic, Limited
99 - SE, Sport, Classic, Limited
00 - SE, Sport, Classic, Limited, Freedom
01 - Sport, Limited, 60th Anniversary Edition

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