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4WD conversion

This XJ started as a factory 2WD. We’re planning the 4WD conversion around the 6.0L swap, with the transmission, transfer case, axles, and driveshafts working as one package.

Built 6.0L LS / torque and reliability first

The goal is dependable torque for trail work and loaded travel. We’re going with a mild, naturally aspirated 6.0L, a conservative cam, and a tune focused on everyday drivability. The donor and internal parts are still being finalized.

Rebuilt 4L80E four-speed automatic

The 4L80E is our current transmission direction for its strength behind the 6.0L. The plan includes a matched converter, dedicated external cooler, and temperature monitoring. Output shaft, adapters, mounts, and clearances will be finalized with the swap layout.

Driver-drop Atlas two-speed transfer case

A driver-drop, gear-driven Atlas is the direction we’re considering for the 4WD conversion. We’re looking at a 3.8:1 low range; the final ratio and adapter package will follow the tire, axle, and transmission choices.

Currie high-pinion 44 / XJ front axle

We’re planning around a reinforced high-pinion 44 with chromoly shafts and a selectable locker for a 33–35-inch road-and-trail setup. Tire size is still open. If the build moves toward bigger tires and harder crawling, we’ll revisit Dana 60-class axles.

Currie 44 / XJ rear axle

A matching Currie 44 with chromoly shafts and a selectable locker is the current rear-axle direction. We’ll match gear ratios and wheel patterns front to rear, then set and weld the spring pads and shock mounts for the finished suspension geometry.

Unibody reinforcement and drivetrain integration

The supporting work matters just as much as the engine. Our plan includes unibody stiffeners, reinforced drivetrain mounts, and driveshafts sized to the finished layout. Brakes, steering, suspension travel, and tire clearance are part of the same build.

Holley Terminator X Max 550-928

We’re planning the same Holley kit model as the Stagea for the 6.0L / 4L80E package. The donor needs compatible Gen IV 58x crank / 4x cam signals, EV6 injectors, and drive-by-wire equipment. The final engine choice will determine the matching harness and controls.

PowerTune 7-inch digital dash

A 7-inch PowerTune display will put engine and drivetrain information where we can see it. The plan includes the Holley interface, coolant and transmission temperatures, oil pressure, voltage, and configurable warnings.

1997–2001 XJ cluster mount / PowerTune 7-inch

The PowerTune will sit in the factory cluster location using a 1997–2001 XJ mount. We’ll integrate fuel level, speed, turn signals, high beam, and warning functions with the new engine controls.

Three-core aluminum LS-swap radiator

A three-core aluminum radiator is part of the cooling plan, with LS hose connections and an XJ-friendly fan and shroud layout. The final unit will be chosen around available space and cooling capacity under load.

Shrouded electric cooling fans

Shrouded electric fans with ECU control are planned to keep temperatures steady on the road and at low trail speeds. Fan wiring, relays, fusing, and alternator capacity will be sized for the full accessory load.

Dual battery system / starting and house power

Dedicated starting power and a separate house battery will keep camp and accessory loads off the starting battery. Isolated charging, secure mounts, and properly fused wiring are part of the setup.

Rooftop tent and load-rated rack

A rooftop tent will make the XJ a more useful overnight rig. Tent and rack choices are still open; we’ll match the mounting and load ratings to the Jeep and keep heavier cargo down low.

JCR Vanguard front bumper

JCR Vanguard rear bumper

Rear swing-outs are not installed.

JCR integrated upper quarter-panel armor with rub rails

Includes integrated taillight boxes; lighting is not included.

JCR Crusader rock sliders

JCR rear-window EDC MOLLE panels

Two panels required for the planned pet divider.

JCR pet divider

Mounts to two rear-window MOLLE panels.

JCR center-console MOLLE panel

JCR rear-hatch MOLLE panel

JCR interior cargo basket

JCR overhead MOLLE panel

JCR Adventure Carrier dual rear swing-outs

The plan is fuel cans on one swing-out and the spare tire on the other. We’re still finalizing the carrier hardware and fit with the existing Vanguard bumper.

Rough Country 12,000 lb Pro Series winch / synthetic rope

JCR battery tray

Planned battery tray. The final battery mounts will be worked into the LS swap and dual-battery layout.

Rough Country 4.5-inch long-arm suspension lift

A 4.5-inch long-arm setup is planned with the future 4WD conversion. This kit lists 4WD fitment; the final configuration will follow the axle and drivetrain layout.

Rough Country MLC-6 light controller

Rough Country 2-inch Black Series pods / amber DRL

Two sets: one in the front bumper and one in the rear. Rear main LEDs activate in reverse. Front and rear amber LEDs follow the corresponding left or right turn signal.

Rough Country 2-inch Black Series pods / cool-white DRL

Rough Country upper-windshield light bar

We’re going with a curved, dual-row Black Series bar with white DRL. The exact kit configuration is still being worked out.

Quality CB radio with a tall whip antenna

A proper CB setup with a tall whip is on the list. We’re still choosing the radio, antenna, and where to mount them.