Projects

May 8, 2006

1991 Jeep Cherokee XJ 2-Door Build Up

This Jeep came to us in shambles. It would barely run and when it did it needed help to keep it running. The paint was weathered to almost nothing, and the body was showing the notorious signs of rust hidden beneath.

After the vehicle was completely gone over all mechanical and maintenance issues where addressed to include: Fresh brakes, lines and hardware, transmission overhaul, new starter, tune-up, E-Brake cables and a few minor odds and ends. Now the Jeep was back up and running in tip top shape.

The next phase was to get it trail capable. We started out by installing a 4 inch TOMKEN "Ultra Flex" lift kit with full leaf springs and adjustable upper and lower control arms. Because TOMKEN didn't intially come with any shocks, we decided to use a set of SKYJACKER's Nitro shocks to help absorb the beating of the trail. To help relieve any additional stress that could play a factor on the XJ's front steering we also added a JKS front adjustable track bar. Due to the fact we knew we would be adding a fairly beefy front bumper with a winch we decided to add the JKS "ACOS" (adjustable coil-over spacers). This way once we added the extra font weight we could dial the ride height in just right. We also added a pair of 1.5 inch greasable TERAFLEX rear shackles to prevent the rear from sitting to low. Once the lift was complete and our ride height was established the NP231 was converted over to a fixed yoke setup using ADAVNCED ADAPTERS slip yoke eliminator kit, and a pair of custom TOM WOODS driveshafts were installed front and rear due to their superior strength. The Dana 35 rear axle was then upgraded with the "Evolution Series Rear Axle Upgrade Kit" also known as a Super 35 kit. Now that we were in the axle we swapped out the old and tired 3.55 gears with a fresh set of YUKON 4:10's to help the xj easily turn the 33 inch tires in its future. While we were taking the front axle apart to regear it we also decided to increase the strength of the known to be weak Dana 30 with WARNs front hub and axle conversion kit. This allows not only the ability of being able to manually unlock its hubs, but also the option opf running a slightly more aggressive locker with out sacrificing daily driving. This kit also strengthens the front axle by an average 30%. We decided to use a POWERTRAX front locker becasue of its simple installation and function.

Now that most of the drivetrain and suspension was complete it was time to protect it all. The front engine/transmission was protected with a 3/16" SKIDROW skid plate. The transfer case also utilized another SKIDROW product which like the eng/trans skid plate was 3/16" thick and tied into both the unibody and transmission cross-member. The Dana 30 front differential was guarded with WARN's black powder coated cover. We also utilized the WARN "Rock Slider Bars" to protect the well known vulnerable rocker panels on the Cherokee.

Now that everything was buttoned up for the most part it was time for some new color for the Cherokee. We decided after already knowing its fate of daily driving and trail running we needed a good coat of that special something to protect it from scratches, gouges, dents, etc. So we decided to mix a custom paint color with some of our PROTEX bed liner and spray the enitre exterior of the Jeep encasing it in its own protective shell. Since the Protex has a slightly rubbery compound it dries hard as a rock but is still very pliable against bashing and tree banging obstacles with out worrying about it cracking. It is also tintable so color matching is never an issue.

Well the body is ready to go, but before it was finshed we still had a few other items to get to. First we decided to open the factory wheel wells a little bit more for not only tire clearence, but to get good articulation with out doing damage to the fenders or rear quarter panels. To do this we used the BUSHWACKER Fender Flare Cutouts, whick also give the XJ an additional 2 inches of tire coverage to allow for a wider tire and keep them covered. Since we didn't have a rear tow point on the XJ yet and knowing the factors that unibodies are under we used a Class III hitch in place of a single tow hook or bumper. This way the load is dispearsed and it has a multifunctional use. Along with the front of the cherokee we had been looking for a super strong bumper that not only had a winch option but would bolt deeply into the XJ's unibody and spread the load out when in use. This is the reason we went with WARN's Cherokee Front Bumper. Made with 3/16" and 1/4" thick plates and allocated for up to a 9,500 lb. winch it was perfect.

For tires we decided to use 33x12.5R15 PRO COMP "Mud Terrains". Aggressive on the trails, yet with enough manners to be used as street tires. The wheels were also 15x8" PRO COMP "Series 152 Steel Simu-Locks".

With the tires being this size we didn't want to take up to much room inside nor did we want a tire blocking the rear window. So we decided to add the KARGO MASTER "Bushman Steel Rack" on the roof with the optional tire carrier to secure and lock our spare.

Lastly we decided to boast the XJ's power with a Stage 1 JET CHIPS performance module and help it breath with a SAFARI Snorkel and K&N filter.

Since then the XJ has performed exceptionally well on over 3 trips to paragon and local spots, along with being a well mannered daily driver. As time goes by we will be sure to update everyone on any mods or upgrades we should add. If you have any questions please feel free contact us here a Jeff Daniels Jeeps!!!