1977 Cherokee build.

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Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

More console pics. I got all the switches and outlets wired. Each panel has a connector on it so they can be easily removed. So yes, two 115V AC outlets. I am using a small inverter that I kitbashed and will reside under the console.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Hopefully I will get the engine started his week, so I needed some pieces to finish the fuel system.

My new filler neck, next to the old.
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Filler pipe from the neck to the tank.
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New vent hose. Got this from McMaster Carr. Much heavier than stock and it is meant to be used with fuel.
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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

More wiring. This is the second battery isolation system along with auxiliary wires.

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The big can is the isolation relay, controlled by the switch on the console. The smaller relay is the 2nd battery charging relay. I need better pics.
1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

So success. The engine fired on the second try. Had to purge the air from the fuel lines. Bad news was I ended up with a large puddle of gas on the floor. So pulled the upper intake off so I could find the leak. Turned out to be from the #8 injector. Bad O-ring in the fuel rail. So replaced it, put the rail back on and pressurized it, this time I had no leaks. I am glad I put in the fuel pump bypass jumper. I just have to connect 12V to the jumper and the pump comes on. No need to run the engine or turn on the key. The only DTC's I got were for the nonexistent transmission. The ECU is looking for the 4R70W that was behind the original engine. Now I will have to drain the tank so I can drop it again.

I only gave the engine starting and running a 30% chance. The engine is a mish-mash of parts. The short block is from a 1990 full size Bronco. It was a roller block though. :-bd The top end and cam are from a 1996 Explorer. The firing order for the two engines are different, with the Bronco using the old order and the Explorer using the HO/351W firing order. Two cylinders are swapped. Everything works though. Idles nice and smooth with good throttle response.

Specs for the engine.

1990 Roller block with rotating assembly from Ford F-series.
1996 Explorer roller cam, intakes, roller lifters, and GT-40 heads. Heads ported mildly on the intake side, aggressively on the exhaust with ports gasket matched to headers.
Summit Racing headers, cleaned up and using stage 8 locking fasteners.

Cam specs:

0.422 / 0.448 lift (1.6 rockers) 0.448/0.478 lift with the 1.7 roller rockers I am using.
256 / 266 advertised duration
116 LSA

My engine compartment.

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The MAF is not in its final location. I just connected it to the throttle body so the engine would run.
1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.
User avatar

Strode182
Posts: 374
Joined: Sat Jun 09, 2012 8:38 am
Location: Littleton, Co

Re: 1977 Cherokee build.

Post by Strode182 »

Looks great, I'm impressed with your work. So it's drivable?

pcoplin
Posts: 452
Joined: Sun Feb 17, 2013 12:46 pm
Location: Beaverton, OR

Re: 1977 Cherokee build.

Post by pcoplin »

Damn, nice work! Clean.
85 Grand Wagoneer 5.2/44RE/NP229
98 TJ 5.9/46RE/D300
97 F250 Powerstroke

G14 Kustoms
Posts: 3
Joined: Tue Jun 04, 2013 4:32 pm
Location: Sheridan, CA

Re: 1977 Cherokee build.

Post by G14 Kustoms »

Awesome build!!! I have a 75 cherokee and a bunch of ford parts. I am planning pretty much the same swap. I will be using a 302 out of a 92 mark VII. essentially the same engine as a mustang of the era. AOD auto and chain drive t-case. Large bearing 9" rear with detroit and HP dana 44 front with ARB. 36" cepeks and 4.56 gears. Thanks for posting all of the pics. You have given me a bunch of motivation and some new ideas. Please keep the updates coming.

Cheers...Matt

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

No, not drivable. I have been in Illinois for the last five weeks for my job so nothing has been done. I did get the hoses for the hydroboost hooked up and the return line. My goal over the next week is to get the cooling system done...ish. Everything except a fan shroud so I can break in the engine. I need to get a new radiator because the one I pulled from the JY was stolen. I know it was stolen by employees of a certain HVAC company, but I have no proof. So I am trying to find one and can't justify $350 for an aluminum one. After that it is getting the windows in and doing the interior, after I string up the battery cables and emission hose. I also have to drop the tank again to replace the level sender. I did wire in a fuel pump jumper so I can easily drain the tank.

Then tires. I am stuck between 33" or 32". I am confounded by a lousy half inch (radius).
1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Five months later...

Yes, I have been working on it. It's winter, so the working goes slower. Especially two weeks ago when we had five nights below zero. I mean, it only got down to -11 F, but it does make the garage a bit chilly, and I just said to heck with it. Anyway...

What I did today. Mounted and wired the condenser fan. It's for when the AC is running. It greatly helps to keep the AC cold. The bracket is 304 stainless so I don't have to paint it.

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My Contour fans.
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Mounting brackets.
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Had to move the rear brake line.
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Dual batteries.
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Unusually routed exhaust. The tires won't rub, and its 2.5" tube.
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The muffler and it's mounts. Yes, there are lots of welds, but this is my third try to get things to fit.

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My post cat O2 sensors. I have no idea if this will pass the emissions ref.

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Two tons of fertilizer in a one ton truck. Batts on right, vapor canister just to the left of it, and an offset axle.

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Fuel lines and brake line. The brake line will be tied up, I was just waiting till I got done with all the rearranging.

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Hydroboost.

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In case one forgot, Saginaw pump on Ford engine. This is a factory Ford Bracket designed to use the Saginaw pump.

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My bling!

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

So, I pushed the Jeep out of the garage and actually drove it around the neighborhood. Moves under it's own power for the first time in 4.5 years. Of course I found some items that will need to be addressed. My front brake hoses are too short. Some moron needs to learn how to measure. My trac bar is too short, so I will get to make another. I need to put some foam rubber between the roof and the interior braces. Going down the driveway the roof was banging against them. Due to using a Caprice steering box, my steering wheel is all wonky. Like my CJ, the drag link will need to be shortened and re-threaded.

On a positive note, the heat and defroster controls work like they should. In case one has an issue with the vacuum switch for the heat/defrost, I found that a few drops of silicon lube on the pad on the left side of the switch works wonders.
1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

I forgot how much freakin' work it is tearing apart and cleaning an axle. I do have all the parts to put it back together though. I just need the time now.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Been a while, but the Jeep is now living outside. Axles are in and all buttoned up. Working on the interior now, which is a pain, including the audio system. Here is my sub box. It's just a little 8" sub, but it works well.

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It is an actual box.

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Installed. Sorry for the light fuzzies.

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Where I put the amp for the sub.

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And the other speaker.

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Door panel in. I had to make a grill/cover for the door speaker due to some DSPO poorly cutting a hole in the door panel for a 6 x 9 speaker.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Some pictures of the front suspension. If you look close, you can see a mouse nest in the frame.

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Other random pics.

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The other money sucker.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Other than those, I know have a functioning parking brake. I will post pictures later, but it involves F-150 brake cables, a coupling nut, and a piece of threaded rod, plus some brackets. Easy peasy.
1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.
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jaber
Vendor
Posts: 3066
Joined: Sat Aug 27, 2011 5:24 pm
Location: Chino Valley, Az.

Re: 1977 Cherokee build.

Post by jaber »

I love the color of your Cherokee. Its looking great, nice work. :-bd
Jeff

'46 cj3a
'51 Willys p/u
'51 Willys Parkway Conversion
'74 CJ5
'75 J-20 Wrecker
'75 J-20 Cummins service truck
'77 J-10 p/u
'79 Cherokee
'88 Grand Wagoneer
http://s252.photobucket.com/albums/hh14/jeffaber/

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

My Parking brake cables. Again, they are from a F-150. I had to extend the original parking brake cable with a stainless steel coupling nut and a stainless threaded rod.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Some more electrical stuff. I want lights on a future roof rack, so I had to get wires through the roof in a sealed manner, so I made a bulkhead fitting, shed a few tears, and drilled a hole in the roof. It is two power wires and one ground. I didn't have room for another wire.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.

Topic author
csuengr
Posts: 1290
Joined: Sun Mar 24, 2013 10:24 am
Location: Sterling, CO

Re: 1977 Cherokee build.

Post by csuengr »

Well, I have been driving the Jeep for almost 5000 miles now, so there are a few issues.

1. My transmission whines. I didn't hear it when I drove the donor vehicle. I guess somewhere in the trans life,someone put gear oil in it instead of ATF.
2. My power steering pump whines. I put in a rebuild kit instead of getting a remaned unit.
3. It took forever to get the engine tuned. Somehow in the calibration, a bit switch, which is supposed to be 0 or 1, had 216 entered instead. The ECU didn't know what to do.
4. It also took forever and much frustration to get the EVAP system to top leaking. I have to comply with OBDII.
5. Had to redo my cats, see later.
6. I ripped off the roof rack trying to pull into a garage.

Pictures.

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Here are my catalytic converters. If you count, you will indeed see four of them. The 5.0 Exploder engine had four, so I need four. Please ignore the dangling connector. I do.

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My receiver hitch. It's a modified one off a 2000 Tahoe.

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1977 Cherokee S, Ford 5.0, 5 speed, BW 1356, 33 x 10.50 BFG's. No longer my DD.
2007 Mercury Milan, 2.3L, 5-speed, now my DD. 29 mpg average.
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jaber
Vendor
Posts: 3066
Joined: Sat Aug 27, 2011 5:24 pm
Location: Chino Valley, Az.

Re: 1977 Cherokee build.

Post by jaber »

csuengr wrote: 6. I ripped off the roof rack trying to pull into a garage.
:o :banghead:

It does look good. :-bd :-bd
Jeff

'46 cj3a
'51 Willys p/u
'51 Willys Parkway Conversion
'74 CJ5
'75 J-20 Wrecker
'75 J-20 Cummins service truck
'77 J-10 p/u
'79 Cherokee
'88 Grand Wagoneer
http://s252.photobucket.com/albums/hh14/jeffaber/

twisted frame
Posts: 637
Joined: Wed Mar 27, 2013 9:41 am
Location: Massachusetts

Re: 1977 Cherokee build.

Post by twisted frame »

Great looking Cherokee that hides a ton of mods. Wow! Extra nice job on those E-brake cables and routing them along the frame. Just wondering - did you happen to need to make a new backer board for your vinyl interior door panels? I'm attempting this soon. Probably going to use some type of plastic sheet.
73 J4000. 360, MC 2100, T18A, D20, stock closed knuckle Dana 44 front, 60-2 rear. Warn Lock-O-Matics, Warn/Belleview electric winch, true duals with glasspacks, old-school front diff skid plate, used 265 Toyos on 16" AR wheels.
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