UPDATE: If anyone down the line reads this thread of mine, and has a similar issue and measurements - I ended up getting the Moog K3171 thermoplastic bushings off amazon, which are supposedly 26mm. When it arrived, the plastic said 25-1/2mm inside (right on the bushing), and they were a super snug and good fit So that solved that! The AC Delco bushings and links were a super great price and fit too.

Hey guys! So I have a quick and annoying (to most probably) questions re: sway bar bushings. I just bought a 1999 Cherokee XJ Classic (4x4, 4 dr, 4.0 auto). The Jeep likes to rock and sway like a boat, not to mention the noises coming from the front end. I suspected the sway bar bushings being shot and sure enough, take a look at the photo (showing the gap between bar and bushing - it almost looks like someone installed a 28mm on a 25mm).

My questions is, just to keep my brain calm and not panicking - Based on the caliper measurement below of 26.6mm (and it was like 26.34mm in other spots), and given the slight rust, I should be installing a 25mm bushing, correct?? (I was told the Classics usually had the 25mm, but when I talked to a guy with a Classic he told me the 28mm fit his XJ...which threw me off. Measuring mine only made me more confused! Never has 3mm made my life so difficult)

Second question: Sway bar links - they were all the same size, across the board, for all XJ sway bars, correct? (I want to buy some stock replacements for now, before I start thinking about lifts and quick disconnects etc).

I thank you all in advance!

It's a silly and quick question, but being a new XJ owner is exciting and at times, also a little confusing!

 

Best thing you can do is just what you did. Measure it.
Scroll down through the options and you'll see bushing for a 26mm stabilizer bar.
https://www.rockauto.com/en/catalog/...r+bushing,7624

For links:
https://www.rockauto.com/en/catalog/...+bar+link,7580

 

Thanks for the link! Definitely confirmed a couple things for me - a) a 26mm is a real thing haha. and b ) the 26mm I wanted to order off amazon, has the same part number as the Rock Auto one. To explain what was confusing me, see photos below. Amazon's part picker says that for my Trim level 1999 XJ Classic, the bushings should not fit. However, searching the part number (K3171) gave me a link to the MOOG website that states 26mm.... and then the Rock Auto 26mm bushing are also a "3171" part number.

So I am 99% convinced that my amazon Bushings SHOULD fit my XJ (reason I want the amazon ones, is that I am also ordering the Links - AC Delco US made ones, for now to tide me over til I do any mods - to get free shipping )

As you saw in my photo, the bar measured 26.6mm (with some rust). So I assume if I take a little rust off, it should still be about 26mm. I don't think a 25mm or 26mm would make a huge difference? (assuming it is 26mm)

Pics of all the info:

 

When it comes to stabilizer bars I don't think there is a specific size for any trim level. Best to measure like you did.

Good you shopped around for the best price. Although Rock Auto most of the time has the best price you also need to check shipping before committing to a purchase. In your case as in some others I'll use R/A as a parts reference.

 

Yup, always best to just grab the caliper and measure the part, to be 100% sure. Googling and searching are all good and fun for info, but if you have the part right before you, and measure it, you're 100% certain.

So to confirm, and making sure my eyes aren't deceiving me: Based on the measurement of my bar I posted, the 26mm MOOG K3171 bushing should be the one I am ordering, right? (I know that there is a K3170, that is 24mm, but I can't see that being a good fit, too tight I'd think, even if I brush some loose rust off)

I just want to avoid any headaches, and having someone experienced here to "hold my hand" a little makes it an easier transaction haha

(I mean, I am mechanically inclined, but I've never actually had to ever buy sway bar bushings in my life! On any car!)

 

When I replaced mine, the parts supplier said there were 2 listed for my 95. 26mm and 28mm, mine turned out to be the 26mm when I measured it. Your original picture is identical to how mine looked.

I would certainly be going with the 26mm ones from your measurements, 24 will be way too tight. If the metal where the bush sits is rusted, give it a good wire brushing down and a splash of grease.

 

Alright! Good stuff, and I love hearing about real world, first hand experience. So I should be going with the 26mm, perfect.

Thanks for that input

 

Couldn't remember what the size of the one on my '96 was or which size new bushings I bought were so I just measured it. No rust. 26mm.

 

While you're in there, take the sway bar off, grind off all that rust and junk and give it a good paint job. Will be a first step to making it easier to work on the front end. Doesn't take too much longer and once you do that for every part you replace everything will be nice and clean after awhile.

 

I don’t believe applying grease to the bushing is the best idea. Some elastomeric materials (rubber like material) can be degraded over time when exposed to petroleum products and grease tends to collect dirt and grit. I have seen no evidence of the use of grease as it came from the factory on any XJ’s where I have replaced the sway bar frame or link bushings. Some aftermarket suspension suppliers caution against applying grease to bushings.

Regarding sway bar link size there are two sizes. This does not apply to your 1999 but this may be useful to others. My previous research showed that up until May 1991 the link used is 7.25” long. After approximately 5/20/91 the sway bar link is 8.25” long.

You do not necessarily have to replace the sway bar links if they are intact and the bottom bushing is in good condition. The top bushings typically take a beating and wear first. Replacing these will likely help more than just the sway bar frame bushing. You may find just the top bushings for a few dollars. Don’t overtighten the top nut when assembling such that the bushing is overly squished and deformed. Placing a jack under the suspension where the coil spring sets makes it easy to line things up.

While you are under there check the bushings on the front shocks. Grab the shocks and shake them – there should be no side to side movement. If they are worn you will have more body movement and possibly some clanking. Also look for signs that the shocks have been leaking oil. I expect the symptoms you described in your original post involve more than just the sway bar frame bushings.

 

10-4 on the dirt and grit. I had a zip tie cut into a metal trans cooling line. Yes there was a small leak so it could gather dust/grit.

 

I did that with my 96 & 98. Repainted them with POR-15. It's approaching a year and they still look great. I also cleaned off the front end of the 98 and got in there with a touch-up gun with POR-15. It's worth the work if you're keeping the vehicle long term.

 

X 3 on a good de-rust and paint

new poly bushes for the swaybars, tightens them up, I just got new links with bushes complete, as they were ludicrously cheap at the time

 

Oh, believe you me... shocks are next on the list haha. They're pretty nasty, and I have leaf spring sag out rear. The plan is either get it up to OEM spec, or just do the full 3" lift with all new parts all around. (Leafs, coils, shocks, bushings and all the hardware). I entirely agree with you that is i most probably more than just the sway bar bushings and also my shock bushings, as they look pretty beat as well. However, I feel it's a TON more work to get the bushings out of that dogbone area of he shock, than just replacing the whole shock with those already in place I am not working out of a garage at the moment, but an apartment building parking lot....tons of fun!

Any advice on the best way to remove the shock dogbone-end bushing, if it comes to that? Use a vise + some large metal pin, to "push" it out?

 

I will for sure be taking a wire brush on my Makita 5" to the sway bar. I need to get all that crap off, and 100% will be repainting it with a rustoleum or tremclad rust-paint. (as that's what I have at home and am on a budget POR-15 isn't the cheapest, for example, but man is it ever good!)

You guys didn't think I'd just take new bushings and slap them on an 'ol rusty sway bar, now did you? What do you think I am.... Canadian? *hides maple leaf*

I was going to go the Poly Route, but there's the math: Entire Poly bushing-only front end kit - $43 CAD - VS - The Moog Thermoplastic frame mount bushings + AC Delco US made sway bar links w/ bushings installed - $39 CAD. It's almost a no brainer, as you said, they are ludicrously cheap to buy (the links)

So I will go with OPTION B. If I hate it in a year, I'll just get the full Poly kit if I am no longer on a shoestring budget haha