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Jeep Rebuild 

This project involved the complete mechanical restoration and modification of a 1997 Jeep Cherokee XJ Sport with a 4.0-liter engine. The work encompassed nearly every major vehicle system, including suspension, drivetrain, braking, cooling, electrical, and interior components. From an engineering perspective, the project provided valuable experience in diagnosing and repairing interconnected systems, understanding how mechanical subsystems interact, and applying modifications to enhance off-road performance. Key lessons included how suspension geometry influences handling, how drivetrain and axle upgrades affect durability under load, and how braking and cooling systems must be maintained in balance with performance improvements. Beyond automotive engineering concepts, the project also developed practical fabrication skills such as metalworking, wiring, and the use of hand and power tools. Collectively, these experiences strengthened both technical knowledge and mechanical intuition, while reinforcing the importance of iterative improvement and performance optimization.

 

Check out the gallery below to see highlights of the rebuild process and final configuration of the Jeep Cherokee XJ Sport.

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Engineering Work Log and Vehicle Modifications

1997 Jeep Cherokee XJ Sport 4.0L

Suspension: Overall 6 inch short arm suspension lift kit, 5.5 inch increased front coil springs + leveling kit, 6 inch increased rear leaf springs, Rough Country shocks, reinforced front travel arms, 35 inch Milestar Patagonia M/T Tires

Steering: Custom steering stabilizer kit, drop arm, upgraded tie rod, upgraded ball joints + bearings, fender flares

Engine: Complete engine tune up, cold air intake and rerouting, transmission rework, upgraded front driveshaft, new engine radiator, added transmission radiator and custom cooling stystem

Brakes: Upgraded front disc brake calipers, disc, pads, lines. Rear disc brake rebuild

Other: 50 inch curved upper light bar, 20 inch hood light bar, off-road front and rear bumper, winch, interior upholstery work, parking brake rebuild

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