This section contains articles about improvements and possibly fundamental changes to your vehicle.
It is therefore your responsibility to maintain safety in and around your vehicle at all times.
It is likely that some procedures featured here may void your vehicle's (or parts thereof) warranty.
It is also likely that some of the articles featured show procedures that may not be legal for street use in some or all states within the US and/or any other countries and may not be safe for (on/off-road) use.
The article's author, nor anyone related to this web page, cannot be held responsible for any damage, failure, or violations of the law, that might result from from following of any of featured modifications, or linked to, on this web page.

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Axle

Axle related projects. Go to Top of Page

Front (and Rear) Dana 44 Conversion with ARB Locker

This extensive project shows the problems and possiblities about how to make a set of Dana 44 axles fit underneath a Cherokee. The article emphasises the construction of a entirely custom front Dana 44 setup.

by Jeff Ayers

November 11, 2000
August 3, 2001

Rear Dana 44 Axle with an Ox Locker

Here an overview about building a rear Dana 44 with an Ox locker.

by Andreas Ritterbusch

September 18, 2001
August 26, 2007

Installing (Adjustable) Ball Joints

Installation and removal of ball joints and how to gain an additional 3.5 degrees of caster!
(caster gain options vary with year.)

by Andreas Ritterbusch

October 4, 2001
August 26, 2007

Pinion Seal Replacement

Short driveway "How-To" for the D30 and D35 axles.

by Scott Rozman

February 3, 2000

Front Axle Seals and Upgrading to 297-X U-Joints

This article was written with the beginner in mind. First, how to change axle shafts (e.g. 260-X to 297-X) and also how to change the inner axle seals (shown here on a vacuum-disconnect D30).

by Andreas Ritterbusch

October 4, 2001
December 11, 2001

 

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Body

Body and exterior related projects. Go to Top of Page

Front Fender Trimming

Front fender trim job to clear those 33-inch tires.

by Jeff Ayers

October 30, 2000

Rear Fender Chop

Rear fender trim job to clear bigger tires.

by Scott Rozman

October 30, 2000

Front and Rear Fender Flare Relocation

Tim's love to detail shows you how a clean fender relocation job can be done right!

by Tim Palen

April 23, 2001
December 5, 2001

Upgrading to Newer Style Door Seals

Installing '97 and up XJ door seals on any earlier XJ/MJ.

by Andreas Ritterbusch

June 1, 2002

Installing LEXAN rear quarter panel windows

Instead of breaking the glass, try this plexiglass-like replacement. Fairly easy to do too.

by Andreas Ritterbusch

May 24, 2004
September 2, 2007

 

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Brakes

Brakes and braking improvement related projects. Go to Top of Page

XJ Rear Disc Conversion Using ZJ Parts

Bill's wizardry takes you to the wonderland of rear disc brakes on your XJ!
(Dana 35 or Dana 44 only).

by Bill Ansell

June 17, 2001
January 29, 2002

Power Brake Booster Upgrade for Pre-95 XJs

This article describes how to upgrade the brake booster in an old XJ using a new style double-diaphragm booster to improve braking performance (with or without swapping the actuator rod).

by Andreas Ritterbusch

June 17, 2001
January 29, 2002

Parking Brake Bracket Relocation for '97+ XJs

This mod shows you how to gain parking brake cable length (2.75") in less than one hour and spending less than half a dollar! For newer XJs with mild (up to ~3.5") lifts.

by Andreas Ritterbusch

June 19, 2001

Extending Brake Hoses Using YJ Parts

This common modification never fails to provide the extra length of brake line that is needed for lifted XJs.
Here shown on a newer XJ with ABS.

by Andreas Ritterbusch

June 21, 2001
July 9, 2001

 

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Bumpers

Front and rear bumper projects, including rear bumper tire carriers. Go to Top of Page

Jeff's Custom Front Bumper

Completely home-made super-duty custom front bumper project with winch adapter plate.

by Jeff Ayers

December 1, 2000
December 6, 2000

Factory Bumper with Tire Carrier

Ever thought how difficult it would be to install one of those older OEM spare tire carriers?
For up to 31" tires only.

by Andreas Ritterbusch

September 15, 2000
June 11, 2002

 

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Drive Shafts

All drive shaft related items, including slip yoke relocators. (For axle shaft related items look under Axle). Go to Top of Page

Identification Guide to Drive Shaft Tech

How to identify a drive shaft related item, a short overview with annotated images.

by Scott Rozman

October 10, 2000

Rear Driveshaft Angles

Get the picture of the rear driveshaft angles!
(Without slip yoke relocator).

by Dave Kamp

December 7, 2000

 

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Electrical

Electrical and electronic modifactions in and around the Jeep. Go to Top of Page

Rewiring the Marker Lights as Turn Signals

This article describes how the side marker lights on the XJ/MJ can be easily rewired so that they too act as turn signals.

by Andreas Ritterbusch

September 17, 2001

 

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Engine

In and around the engine bay. Engine and engine related projects. Go to Top of Page

Overview: A Stroker Story

Dave Morris shares information regarding research about the possiblilitis and various options on how to stroke a JEEP/AMC 4.0L engine. An overview.

by David Morris

February 3, 2001

4.0L Stroker Calculation MS Excel Spreadsheet

Microsoft Excel spreadsheet file to do some general stroker calculations.
(Heavily modified version of Greg Friedman's original Excel file)

by Greg Friedman,
modified by Andreas Ritterbusch

March 10, 2002
March 21, 2002

Engine Main Bearing Replacement

Hoping to postpone that engine rebuild?
Maybe, --check this out...

by Scott Rozman

February 3, 2001

Adjustable MAP Sensor

Low-cost home-brew solution on how to build a custom adjustable map sensor.(Article moved Bill's home page).

by Bill Ansell

April 11, 2001

'93 XJ to '00 XJ CCV Upgrade

How to improve a 1993's HO I6 valve cover using 2000 XJ (or newer) parts.

by Jeff Ayers

April 21, 2001
November 19, 2001

Oil Filter Upgrades

Several ways and combinations to upgrade from the metric filter ('87 through '90 non-HO 4.0L) to the more common SAE filter thread as well as upgrade combinations to a larger style oil filter.

by Andreas Ritterbusch

August 23, 2001
April 13, 2002

Relocating the Battery (4.0L, Using a Diesel Battery Tray)

For those who either need to relocate the battery for an on-board air (i.e. York style) conversion, or plan on a dual-battery setup.

by Andreas Ritterbusch

June 3, 2002

Budget Cooling Upgrade (Closed to Open)

A creative low-cost conversion for early 4.0L XJs/MJs from the closed cooling to an open cooling system.

by Joe Thompson

November 2, 2001

Custom installation of a air intake system

Featured here is the custom fitting of an Intense Performance air filter system neatly tucked away under the hood of a '98 XJ.

by Jeff Ayers

February 24, 2004
September 2, 2007

Custom Deep-Water Air Intake

A creative low-cost alternative to a snorkle.

by James Jezak

October 21, 2002

Late Model XJ Oil Filler Cap

An annoying but common situation is a stuck oil filler cap on late model XJs. Here a quick fix and/or replacement demonstration.

by Andreas Ritterbusch

June 22, 2002

Adjustable Thermostat Switch Diagram (PDF)

This Acrobat (.pdf) file is a wiring diagram for an adjustable thermostat switch for electric engine cooling fans.

by Dave Kamp

May 15, 2002

 

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Failures

Things that failed and/or did not work. Custom items as well as commercial parts. Don't buy or build dangerous parts! Go to Top of Page

Delicate Stainless Steel Brake Lines

These brake lines are often used to compensate when a vehicle is lifted. However, they do not provide the strenght of the original brake hoses. Look for yourself.

by Andreas Ritterbusch

December 10, 2000

 

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Funtastik

Fun and Fantasy. Even technical things can be fun. Go to Top of Page

Punkins

See for yourself... Things do get spooky around here. The Dark Side is this MAD Site.

by Authors from the Twilight

October 27, 1756
October 31, 1888

 

Home

Interior

Projects to improve the interior. Go to Top of Page

Adding Floor Drain Plugs for those Deep Moments

Ever got deep (too deep?) into water? Here's how to drain it out of the interior.

Scott Rozman

October 30, 2000

 

Home

On-board Air

On-board air related articles. Go to Top of Page

Single-belt On-board Air with A/C

Get some ideas on how to install an additional compressor, such as the populart York, for on-board air that there when you need it. This installation uses the existing serpentine belt without adding an additional belt. The original Sanden air compressor is kept for a fully functional A/C system!.

by Andreas Ritterbusch

October 30, 2002

Machining a Dual V-belt York Pulley to Fit 6-Groove Serpentine Belt

Make a custom serpentine belt compatible pulley out of the original dual V-belt pulley.

by Andreas Ritterbusch

May 22, 2004

 

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Rocker Panels

Various ways of adding rocker panel protection or welding in new rocker panels. Go to Top of Page

Extreme Duty Replacement Rocker Panels

3"x4" Custom rocker panel replacement using box steel to withstand any trail abuse there is.

by Scott Rozman

August 26, 2000

Extreme Custom Heavy Duty Rocker Panels

Completely custom-made hard core custom rocker panel replacement. Possibly the most complicated/sophisticated way of building weld-in rocker panel replacements.

by Jeff Ayers

September 21, 2000

Serious High-Clearance Rocker Panel Replacement

2"x6" Custom rocker panel replacement with ultimate ground clearance gains, requiring the doors to be shortened! Rockers setup as air tanks also.
Heavy hacking ahead!

by Andreas Ritterbusch

December 12, 2001
June 1, 2002

 

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Roof

Roof related projects, such as roof racks, etc. Go to Top of Page

Aluminum TIG Welded Roof Rack

A custom roof rack for the Jeep Cherokee.

by Brian Peterson

January 29, 2001

Roof Rack Tire Carrier for Aftermarket Cross Bars

A roof tire carrier for spare tires that do no longer fit in the interior location but also should not block rear visibility nor hatch access.

by Andreas Ritterbusch

June 19, 2001
June 29, 2001

 

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Suspension

Suspension related projects. Go to Top of Page

Econo Coil-Spacer Lift

Make your own lift at a super-low budget! (Front end).
This article is a true MADXJ classic and created a lot of interest over the past years.

by Scott Rozman

November 15, 2000
March 26, 2001

Highly Customized "Evolver" Shackles

Ingenious drop-down shackles, --a classic home-brew by Bill Ansell.

by Bill Ansell

April, 2001

Rusty's Track Bar Mount

Cracked welds! Fixed with a 1/4" plate to make this this part safe again.

by Andreas Ritterbusch

April 22, 2001
July 30, 2002

Reinforcing the Lower Control Arm Brackets

Improving XJ lower control arms with MJ brackets.

by Scott Rozman

October 30, 2000
March 26, 2001

WJ Lower Control Arms installed

Brandon's upgrade to WJ lower control arms to clear LT235 tires without any rubbing whatsoever.

by Brandon Shehan

January 10, 2002

 

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Tires

Everything related to tires (except tire carriers) and wheels. Go to Top of Page

Dave's Wheel Physics

Shown are the various forces excerted on the tire, wheel, and related parts.

by Dave Kamp

November 1, 2000

Dismounting a Tire Without Effort

Dismounting a tire can be surprisingly easy with the right tool(s)!

by Andreas Ritterbusch

February 2, 2001

 

Home

Transmission

Manual and automatic transmissions and transfer cases. Go to Top of Page

Transfer Case Upgrade to 6-Planetary Gear

Install a 6 pinion planetary set from a Chevy NVG241 transfer case and upgrade to a wider chain and sprockets.

by Jeff Ayers

March 1, 2004

 

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