Turn your Jeep Cherokee XJ into a trail-worthy machine with the help and tips in this how-to book.
The Cherokee is quite the capable 4x4, especially when modified the right way, and this guide is not about building an off-road only vehicle, or a chrome-covered rig, either.
This manual is about turning your Cherokee XJ into a useful 4x4. One that will feel right at home in the mountains, the mud, snow, desert sands, as well as on the streets.
Author Eric Zappe explains:
How to upgrade your Cherokee's suspension, axles, differentials, engine, transfer case, wheels and tires, skid plates, and more.
And you can do all of this yourself, using aftermarket and salvage yard parts. The book also includes basic 4x4 driving and recovery techniques, plus a number of built-up Jeeps that will give you plenty of ideas for your own Jeep Cherokee.
Book Excerpt: Jeep Cherokee XJ Builder's Guide 1984-2001
CHEROKEE BASICS
BUYING A CHEROKEE
Whether you're looking for a Cherokee to buy or you already have one, you need to know what you're starting with. There were several changes to the XJ during its 18-year production run, and some of those changes have a big effect on how the XJ will perform off-road, either stock or in the beginning stages of your build-up.
If you're looking at doing an extreme build-up, just about any XL will do, since you will be swapping out a lot of the stock drivetrain. But there are still some important considerations, especially for most readers who'll likely be using some or all of the stock drivetrain to start out with. Below is a listing by year of what to look for, but please refer to Appendix A for a more detailed listing of stock specs.
SUSPENSION UPGRADES
2-INCH BUDGET BOOST
A "budget boost" usually refers to a lift kit that affordably lifts the XJ 1.5 to 2 inches. There are very few parts involved in a budget boost, so it is usually easy to install and inexpensive, hence the name. Most all lift kits in this range use a coil spacer (usually 1.75 inches thick) inserted between the coil springs and the body. Because the stock coil springs are retained, you can expect that the handling will not change much from the stock height.
There are three common ways that budget boosts lift the rear. One way is by replacing the stock leaf-spring shackle with a taller one. You can also insert an add-a-leaf (AAL) into the stock leaf pack (if this method is used, I recommend a long AAL, which will support the stock leaf pack better than a short AAL). The third method of lifting the rear is to insert a block between the leaf pack and the axle. Depending on which method is used to lift the rear, the handling may or may not be affected. Using the extended shackle, you can expect little change in the way it rides.
If you choose the AAL, you'll definitely notice a change, as most AALs stiffen the leaf pack considerably. Whether that stiffness is a change for the better or worse is subject to personal opinion. Using blocks can sometimes lead to axle wrap, especially if you have a heavy right foot. Axle wrap is when the leaf springs flex into an "S" shape under heavy acceleration. This can cause adverse effects such as driveline vibration as the bending leafs push the pinion upward.
TABLE of CONTENTS:
About the Author | Acknowledgments | Introduction
Cherokee Basics
A Brief History of the Jeep Cherokee | Buying a Cherokee | Can My Stock XJ Go Off-Road? | Shifting into 4WD | Basic Driving Tips and Techniques | Responsible Use ? Doing Your Part | Basic Maintenance and Do-It-Yourself | Beginning Modifications — Sway Bar Removal
Wheel and Tire Selection
Beadlocks | Wheel Size | Backspacing and Offset | Wheel Spacers | Tire Size vs. Lift Height | Correcting the Speedometer | Tread Types
Steering, Alignment, and Brakes
Heavy-Duty Stock Steering Replacements | Over-the-Knuckle and Cross-Over Steering Systems | Drop Pitman Arms | Steering Box Reinforcement | Alignment: Toe, Caster, and Camber | Death Wobble | Rear Disc Brake Conversion
Axles, Gearing, and Traction Devices
Stock Front Axles | Stock Rear Axles | Alloy Axle Shafts | Popular Axle Swaps | Choosing a Gear Ratio | Manual Hub Conversion | Limited-Slip Differentials | Lockers
Transfer Cases and Driveline
Front Driveshafts | Rear Driveshafts | Slip Yoke Eliminators | Long-Travel Yokes | Shims
Engine and Transmission Upgrades
The 2.5L I-4 Engine | The 2.8L V-6 Engine | The 4.0L I-6 Engine | Snorkels | Air Filters | Bored-Out Throttle Body | Aftermarket Exhausts | Using an Oversized Oil Filter | Transmission Upgrades
Body Basics
2-Door vs. 4-Door | Unibody Strengthening and Stiffening | Fender Trimming | Flare Options | Hood Vents | Bedlining the Interior
Skid Plates and Recovery
Front Recovery Points | Rear Recovery Points | Transfer Case Protection | Gas Tank Protection | Differential Guards | Control Arm Protection | Rocker Panel Protection | Where to put that spare tire? | Basic Tools for Recovery | The Reno 4x4 XJs do the Rubicon
