Trucks

Project Cherokeeper: Blown Head Gasket! Time to Rebuild the Jeep 4.0 Engine Top-End

Submitted by Dan on Thu, 07/19/2018 - 11:06

An overheating issue really had me stumped for a very long time. It had the characteristic of a mild blown head gasket (it would only run hot on the highway, no other problems), but non of the physical symptoms - no coolant visible in the oil, no oil in the coolant, no smoke in the exhaust, compression was great on all cylinders (cold engine), it passed the combustion "block test" both with the rental kit from a parts store and when I took it to a local garage with an emissions test machine, and it passed the cooling system pressure test. Finally, I sent an oil sample to a lab and they said there was signs of coolant in the oil - not a lot but enough for concern. Off with the head!

jeep cherokee 4.0l engine head rebuilt top-end restoration blown head gasket

How to: Jeep Wranger TJ mirrors on a Jeep Cherokee XJ

Submitted by Dan on Mon, 12/11/2017 - 16:05

I've always hated the mirrors on my 1997 Jeep Cherokee XJ. They're too small and they look dumb! A rugged, manly vehicle deserves rugged, manly mirror. Right? I got these mirrors from Amazon for less than $40 for the pair and I'm really happy with them. They're for a TJ Jeep Wranger but they also look like YJ mirrors. 

installing wranger tj mirrors on a jeep cherokee xj

Booger welds galore! I made a homemade skid plate for Project Cherokeeper

Submitted by Dan on Wed, 11/22/2017 - 15:16

Project Cherokeeper -- my 1997 Jeep Cherokee XJ -- needed a little protection for its soft belly. The aluminum transfer case is totally exposed and if it hangs up on a large rock, it can crack. And if that happens, neither axle is moving and I'm going nowhere. Here's how I built my own.

Project CheroKeeper: fender trimming & hood vents

Submitted by Dan on Mon, 07/10/2017 - 15:50

The technique for cutting the sheet metal is an old, tried-and-tested process in the Jeep XJ community. Just search youtube or any jeep forum and you'll see the same method each and every time. Trim the sheet metal up front, and "cut and fold" the sheet metal for the rear fenders. What I did was I tried to trim off just a enough so that there would still be a little tiny metal fender flare left. This meant cutting right along a bend in the sheet metal - which also meant the shape/profile of the fender arches would remain mostly stock - or, in the case of the rear, cutting up to that bend and folding the sheet metal over at that point. This also allowed me to keep the windshield wiper fluid reservoir hidden between the outer fender and the inner fender. After trimming the sheet metal, I cleaned them up with some truck bed liner paint, and the end result looks great and functions beautifully. 

Project CheroKeeper: cooling system overhaul

Submitted by Dan on Mon, 07/10/2017 - 11:30

This story, chronically my attempt to overhaul the jeep XJ's cooling system and overcome a mysterious overheating problem, was orignally posted to the website cherokeeforum.com. I ended up replacing the entire cooling system except for the heater core, and in the end it's vastely improved yet the motor still runs a little hot in the summer. 

Project CheroKeeper

Submitted by Dan on Fri, 03/03/2017 - 16:02

The Jeep -- which I'm now calling the CheroKeeper because it's a keeper ;) -- is finally in my hands! Just as suspected, it has the venerable Christler 8.25" rear end w/ 29 spline axles and np231 transfer case. The mechanicals are in virtually perfect working order. I took it on it's first ever off-road excursion and I was actually surprised at how smooth the jeep conquered those rather large ditches and mud holes. The 4wd worked flawlessly and there was even a little mud to play in.

jeep cherokee xj stock flex offroad 4x4

New project! A '97 Jeep Cherokee XJ with 244,000 on the clock

Submitted by Dan on Fri, 12/16/2016 - 11:24

I'm buying a site-unseen '97 Jeep Cherokee XJ for $1,500! This thing was owned and garage kept for the last 19 years by a nice, older lady who never abused it and maintained it religiously via the dealership, and the Jeep comes with a stack of service receipts as thick as pea soup. That's the only way I would buy any vehicle with 244,000 miles on the odometer...

Chevy GMC Squarebody Trucks Service Manual Free Download

Submitted by Dan on Mon, 01/11/2016 - 12:22

Download it here, for free. I found a copy of the 1984 GMC Light Duty Truck Service Manual. It will of course work for Chevrolet trucks, not just GMC, and for years 1981, 1982, 1983, 1984, 1985, 1986 and 1987. It will also mostly work for years 1973, 1974, 1975, 1976, 1977, 1978, 1979 and 1980, though a few things will be differest such as windshield wippers, front sheet metal, interior, etc.

$50 paint job! or: How to paint your truck/car with Rustoleum and a Roller (part 2)

Submitted by Dan on Mon, 10/19/2015 - 15:30

There was no way I could afford a pro paint job. I gave myself an allowance of $1500 to restore this truck which included much much more than just a fresh paint job. So an expensive paint job just wasn't in the budget. Then I started looking at alternative methods, like plasti-dip. But when I did the math, a plasti-dip paint job would have cost $400 at least and would not be a real investment into this truck. Of course I could have gotten a dozen spray cans and bombed it, but I wasn't interested in something with basically no quality at all. Then I came across a youtube video of someone painting a small red car with rustoleum and a roller. And it looked great! I started watching and reading more and more. The rolled on version was much harder, shinier, and more durable than with spray cans. I was sold.

The (in)famous $50 paint job! or: How to paint your truck/car with Rustoleum and a Roller (part 1)

Submitted by Dan on Thu, 09/03/2015 - 13:28

The idea is that oil-based enamel paints from your hardware store can be ROLLED onto the vehicle if you thin heavily with mineral spirits and use a high-quality foam roller. The mineral spirits help it level out while it's drying and its supposed to make the paint cure faster so you can wet sand the next day. A glossy, flat, durable (relative to, say, a rattle can paint job) finish can be achieved with a very small amount of money. However, it's very labor intensive. 

Chevy K10 truck restoration Phase 5: Suspension and Wheels

Submitted by Dan on Fri, 08/21/2015 - 13:54

What I'm about to do is not going to be incredibly popular with the chevy squarebody community, especially the off-road bunch. I'm going to remove the 4" suspension lift and drop it down to stock height. This was the plan all along with this truck. I'm not into mudding. Since buying this truck I tried a few times and it was just alright but the most fun I had off-road I could just as easily achieve with 33" tires and no suspension lift. In addition, the gear ratio in my GM 10 bolt rear end was only 3.42, much too small for 35" tires even with a SBC 350 engine. I live in a hilly area and on several occasions I got in a jam while going up hill in top gear at 30mph, and the truck did not like that. Smaller tires will make it muuuuch easier to drive around town with the Muncie SM465 transmission, although it will lower my highway speed. 

chevy k10 squarebody front suspension

Chevy K10 truck restoration Phase 3: Front Clip Swap

Submitted by Dan on Thu, 05/07/2015 - 10:06

I'm swapping front clips. Going from the square headlights to the round headlights. Why? Because I like it better, that's why. This is my project, I have a design goal in mind, and this is what I must do to achieve it. I want to turn my 80's truck into a 70's truck, make it more of a classic, more retro. Cooler. Honestly, it's about more than the round headlights. Mainly I want the older style fenders that allow for the really cool chrom trim.

There are no photo-documented tutorials for how to do this swap. None online that I could find. Therefore, I hope this information can be added to the collective knowledge of the squarebody community. 

Chevy K10 truck restoration Phase 2: Body Work and Rust Removal, Part 2

Submitted by Dan on Thu, 04/30/2015 - 14:21

More body work! I'm swapping front clips because I like the round eye headlight style and the fenders that go with it will allow me to use the older style chrome trim. But the front clip I found off a 73 or 74 c20 has a lot of rust and will need work. The learning experiment continues, this time I learn how to weld patch panels with a flux-core, wire-feed welder.

Chevy K10 truck restoration Phase 1: Acquisition & Engine Rehab

Submitted by Dan on Mon, 04/27/2015 - 14:54

After completing my book, I needed some mental rehabilitation. Something therapeutic and relaxing. I also had a (small) wad of cash from the deal so I decided to buy an old truck! I found this old guy, I've named him Hank, someone's old hunting truck. It belonged to an older gentleman in Wyoming and he gave it to his grandson who was entering the marines. The grandson drove it to Missouri and sold it to the guy I bought it from. I have no idea at what point in the truck's life that the engine was swapped out for a 350 and it was converted from 2wd to 4wd! The VIN shows it's a 2wd truck but it is most definitely a 4wd. So it was either converted to 4wd, or a cab with the exact same color scheme was swapped (unlikely). Someone put a lot of money into this truck, and it's kept it's value pretty well. Only a loose bolt and little bit of rust here and there (I'll soon learn just how "little").