'95 Cherokee progress thread.

[StevenS10]

Hey all,
I'm not new to off-roading, but I just got my first 4x4 of my own, a white '95 Jeep Cherokee 4.0 2-door with an automatic, and no mods.
Well, it has P235/75R15s instead of 215s, but so what? Anyway, I started a similar thread on the Cherokee forum, no interest from them.
I have an Explorer axle I intend to swap under this, I'm planning on 35s on 8s with 4.5" BS to tuck them in, traction diffs front and rear, fabricating my own rear tire carrier, and fabricating my own roof rack. Also a class 3 rear hitch, fabricating my own front to match, so I can plug a winch into either end.
At some point my AW4 will get swapped for a 42RH ( A500 )
I'm still doing spreadsheets on various axle ratios, probably 3.73:1 at a minimum in case I decide I need 30-spline front shafts, probably not more than 4.10:1 because those are common in the salvage yards, as are 3.73s, but 4.56:1 isn't.
My first purchase will be front lift coil springs, I have an '87 S-10 I'll be taking rear leafs from. I have a couple of other 31-spline 8.8" diffs already, so my collection includes an open, and a welded, and a freshly rebuilt Traction-Lock set up very tight with an extra friction on each side.

 

[Bart]

Congrats on the new, to you, XJ. I love the 2dr models. Your plans sound like a good start to a project. If I were you I work hard to find some 4.10s. 3.73s will barely work with 35s, and your gas mileage will suffer. Personally, I wouldn't bother switching the AW4, but that's personal preference. Good luck on the build and keep the updates coming.

 

[N-Smooth]

At some point my AW4 will get swapped for a 42RH ( A500 )

Ummmm what? I can't imagine why you'd want to do that but I'd love to hear it.

Also, 3.73 gears with 35's will be miserable IMO. Even 4.10's would be lousy. I wouldn't go with any less than 4.56, probably 4.88 in fact.

 

[Gravy]

The AW4 is bullet proof. Leave it alone.

Find yourself some spare front shafts and go have fun.

I like 2 doors!

Remember the Explorer 8.8 is 3" narrower than your stock rear axle so plan on running 1.5" spacers on each side to compensate.

Listen to Nate, 4.88's are the way to go with 35's on a Cherokee. (I've done both and would highly recommend 4.88's). It's a real consideration that you'll lose some pinion strength with the 30, but if you plan to drive it on the road it's the correct gear choice.

 

[StevenS10]

Thanks guys!
I realize my 4.0 isn't the same as the GM 3.8L and 4.3L V6 I have experience with, and I know I'll need a little extra cruise RPM because of the 35" tires, so I'm looking to end up at 1900 RPM at 65 MPH. I'm leaning toward the Dick Cepek Extreme Country.
My rEsearch says I should have the larger front outer U-Joints, Spicer 297-size rather than 260-size, and I'm planning to swap to Spicer 760s before trying the 35s.
The AW4 is computer-controlled, the 42RH isn't, has similar ratios, can be bolted to the 4.0, and can be bolted to the NP231, with the correct output for the 231 input.
I'm looking for a used 2-barrel intake at Pick-N-Pull, and a points distributor with vacuum advance, I'll be adapting a Rochester DualJet. I plan to drive it EFI, but keep the fry-proof parts in a lead box in my basement, along with an Optima red-top, a spare alternator, and a spare starter. Yes, I'm one of those guys. That's why I bought it, that's what I'm building it for, and that's why I'm looking to improve my skills and teach my new wife what I know.
Looks like the 4.10:1 with the 42RH's 0.69:1 and the Cepek "35" at 33.756" ( standard correction of 97% of 34.8" Summit's website shows for these ) is only 1830 RPM, which might work, but I'd rather be closer to 1950 or even 2000. 4.56:1 would be 2034, but the cost jumps at least $ 300 extra.
IF I can find a D30 Gov-Lock in a Volvo turbo at Pick-N-Pull, I'll probably try that, an Aussie for the D30 would be $200 extra.
I considered doing a big-brake upgrade, I designed and built my own last year for an '83 RX-7 I built, but I'm not convinced I'll need it here. The RX-7 came with 9.5" front rotors and rear drums in 13" 4-lug wheels, I gave it 11.75" x 1.26" front rotors with Brembo 4-piston calipers ( from a Mercedes 430 ) in 15" 5-lug wheels, and 11.5" x 1" rear discs with '84 Z28 rear calipers. I spent several hours on Napa's website finding larger front rotors that would work on my XJ, but noone responded. I was thinking 16" wheels.
With the axle width issue, I have another 8.8 from an '03 E150, I'll have to measure it. But it is 31-spline. Or I have a GM 10.5" FF 14-bolt, already 4.10:1 and welded, changing hubs would reduce it from 67" to 63". Too many options.

 

[N-Smooth]

Yeah the AW4 is computer controlled but it is an amazing transmission.

Forget about the numbers for cruising RPM's because it doesn't factor in the 20 year old, tired motor.

 

[N-Smooth]

Ignore my comments since you seem to have your mind made up.
On a separate note I have a D30 Aussie locker I'm about to post for sale if you're interested. It's used but was functioning perfectly when pulled. It's a sponsorship situation so I got a new one.

 

[OrangeSkidPlate]

Sounds like an interesting build, Nate, give me your locker and I'll write Nate is my hero on the side of my xj.

 

[mbryson]

I'd stick with the AW4 over the Chrysler transmissions EVERY time. In fact, I'd want to swap the AW4 for the Chrysler trans

 

[Herzog]

Yeah the AW4 is computer controlled but it is an amazing transmission.

I'm still running my 1989 AW4 in my buggy. I love that thing.

 

[Rock Taco]

Yeah the AW4 is computer controlled but it is an amazing transmission.

Forget about the numbers for cruising RPM's because it doesn't factor in the 20 year old, tired motor.

nor does it account for the extra weight you will be adding in accessories.

 

[StevenS10]

I got the idea that maybe an early AW4 would have a real VB, but I found instead a couple of ways to control it with switches, no computer needed. That looks like the best option so far.
And age / mileage has nothing to do with cruise RPM, my '89 S-1- 4.3 had 282,000 miles on the original engine, it managed to out-accelerate my dad's '02 S-10 4.3 from a dead stop, with the same gearing and tires. It was fine with 1800 @ 65.