Ok folks,

If you guys remember a while back I was given a 95 XJ 2D 4x4 Manual w/ 4.0 HO. Well, Ive taken it on the road a bit and now it’s time for new front end, steering and suspension components.

Here’s what I’ve done so far.

5 New Tires 30x9.5 on 15s Toyo ATs
New shocks - all 4
Fuel Filter
Cleaned Throttle Body
Replaced 02 sensor
plugs, wires, cap @ rotor
new coil pack
new motor mounts and trans mount
new exhaust hangers
new cross member
rebuilt NP231j T-Case
New Flywheel, clutch, pilot and throw out bearings
FLushed trans and t case fluid
changed oil and oil filter
air filter
wiper blades
drive shaft u-joints
new battery
new headlights

Here’s what Im doing next:
ball joints - upper and lower
track bar & bushings
Stabilizer bar, bushings and links - front and rear
control arms - upper and lower
Tie rods/ends
drag link
Steering dampener
Front coil springs
rear leaf springs & bushings
oil pan gasket

Question:
1. Any kits I should consider?
2. Also, the rear stabilizer bar is pretty rusted. Having a hard time finding anything to replace it with. Any suggestions? Whenever I go over a bump it sounds like the rear is being hit with a 2x4. Im guessing that this is the rear stabilizer bar/links. Any reason to think differently?
3. Anything else I need to take care of while I’m at it?

Keep in mind that this thing was beat when I got it. The motor and trans will need to be gone through at some point but in the meantime, Id like to drive it on dirt roads and on the highway until it needs a rebuild. Im burning (carbon ring on the end of the exhaust tip) and leaking oil (mostly from oil pan, front). The hope is to get another 30k on the clock before I pull the motor and trans for a rebuild. At that point I’ll be replacing the axles and installing a lift (3.5in) and frame stiffeners and bumpers. Until then, Im getting all of the drivability issues worked out and the interior sorted.

Just take it out. A lot of folks here, including me, got rid of it during our lift install process. After you do that, hit some bumps and see if the clunk is still there.

Will do, thanks!

I would not recommend removing the rear sway bar, especially if you ever intend to pull anything behind you. Get new bushings, and links can be purchased on Amazon for under $50 for the pair. If you don't like the rust, take a grinding wheel to it and clean it up, then paint it. There are also replacement bars, just google it and there are plenty of options. You can also get quick disconnect links for the rear just like there are for the front if you intend to do some intense off roading

The rear isn't needed, the up country package came without one from the factory, and they were rated to tow just as much as the rest of them.

I doubt the sway bar is giving you a clunk like you're being hit with a 2x4. I'd suspect that it's something with the rear springs. When I did the springs on my 95 one of them -literally- fell apart in my hand from the rust.

Take a good look at the mounting points for the suspension stuff. If you've got substantial rust, you need to make sure all the brackets are all connected soundly. You may need some welding.

Also check under your back seat and make sure the jack isn't bouncing around or anything like that.

Good call on the rear spring. I didnt think if that. I’ll check it tomorrow morning. I plan on replacing them too, as well as the fronts to get back to stock ride height. I do plan on towing a bass boat or a camping trailer, not a camper but a trailer with camping stuff... Anyway, Im hoping with the heavy duty springs all around and the new track bar and the rest of the front end components that I’ll do okay with out the rear sway-bar.

Well, if you do plan on towing anything, then I will have to contradict myself and say you should keep the rear sway bar. Though the factory Upcountry option came without one and was rated to tow the same as all other Cherokees with the 4.0, a little bit more stability will not hurt anything - especially when hauling a trailer.

Mine tows fine without a rear swaybar. This was back when I only had a 3" lift and 31s.

[QUOTE=00t444e;3569744]Mine tows fine without a rear swaybar. This was back when I only had a 3" lift and 31s

It will still tow fine without it, but it will increase stability when towing is the point being made. The weight it will be rated to tow won't change if it's on there or not, per your previous point about the up country package, but it will only help with the stability. Seeing as the XJ is a unibody, and isn't REALLY designed to tow a whole lot, I would definitely suggest having as much stability as possible.

I really don't think XJ's were built to tow very much if anything, period. At least that's how I approach it from my end. Either way, the rear sway bars car be easily rebuilt with a wire brush then repainted. Just take a good look at your bushings to see if they need to be replaced or not. New ones are cheap. I'd guess the 'clunk' is also from your rear leafs and not the sway bar.

Manufacture rated it to tow 5000 lbs. with an aux trans cooler so obviously they built it to tow something.

They certainly can... just sayin mine gets "ornery" when I try to tow anything.

I'll agree that the XJ isn't the ideal tow vehicle, the only reason I towed that car with mine was because my F250 was down at the time, and I needed to haul that car to the scrapyard, it was only a few miles away and I didn't get above 50 so it wasn't that bad. I definitely would not get on the highway with a load like that. However towing a small utility trailer or boat is no problem for an XJ.

I know my Dad would tow a small trailer with his 94 and Jordan96XJ - a respected member of this forum and very smart and careful guy - tows a small camper with his XJ without concern.