Modified XJ Cherokee Tech XJ (84-01)
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Budget Builds: XJ Upgrades

Old 04-03-2011, 01:17 AM
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Year: 1996
Model: Cherokee
Engine: 4.0L HO
Default Budget Builds: XJ Upgrades

hey my other thread of this nature was turned into a sticky in OEM tech....this is a little more advanced and not all jeep OEM material so here is the updated version.....enjoy!

Feel free to post your mods and links to build threads if you have them.....this thread is to help guys on a budget build their rigs.

***note that these are not all bolt in mods, but can be done by most who are mechanically inclined with the right tools

Here is the latest re-cap of what we have found:

Suspension & Lift:

-Front End:

1.ZJ V8 Upcountry Coils = 1-1.5" lift
2.F-150/Bronco Coils ('70s-ish) = 4-4.5" lift
3.Camaro Spring Isolators = 1.5" lift
4.ZJ spring isolators = stronger, metal core, can be stacked
5.Thunderbird Front Coils ('83-97) = 3-4" lift (varies in lift and softness by year and trim package), will need top plate from strut too
6.TJ Lift Coils (front only) = provide 1" less lift on an XJ than on a TJ
-Rear End:

1.Bastard Pack: Any 2.5" wide leaf spring can be used between to make a bastard pack (they may differ in stiffness and lift) i.e. S10, Dakota
2.MJ Shackles = 1/2" lift
3.GM fullsize pickup shackles ('95-99) = 1.5" lift, better shackle angle
-Misc:

1.JK shocks = slight mod to fit 2-4" lift (must be from JK Rubicon, BPEs are not required, you need to press out the metal sleeves from the JK shocks, and insert the XJ stock bar pins to the axle-side part of the front shocks, and the body-side of the rear shocks.)
2.S10 Shocks (Rear only) = good for the lift you will get when you do a bastard pack
3.Ford Exploder rear sway-bar links = may be good for 3-4" lift
4.WJ rear sway bar end-links = minor fab to fit 3-4" lift
5.WJ LCA's = more tire clearance (some grinding required)
6.WJ rear LCA's = replace XJ front LCA's, 2" longer to accommodate a lift, some grinding required
7.V8 ZJ front sway-bar
8.JK rear UCA = use as XJ LCA, its about 1-2" longer
9.Ford Bonco II (thats the little one like a ranger) Front Swaybar = good for 3-4" lift

Brakes:

-Booster, MC, etc:

1.WJ brake booster, master cylinder, proportioning valve
2.ZJ brake booster, master cylinder, proportioning valve = may need for disc conversion
3.XJ '95+ brake booster and master cylinder = dual diaphragm, larger bore
4.WJ Rotors/Calipers = bigger brakes and more stopping power (will fit 15" rims)
5.KJ disc brake set-ups can be used for a conversion on your XJ axle
-Lines:

1.YJ Brake Lines = 3-4" longer
2.Dakota Rear Softlines ('95-00) = 6" longer
3.GM C/K1500 Front Softlines ('90-95) = 6" longer
4.Dodge Ram Van Brake Lines = 10-12" longer (for big lifts), some dispute
5.JK Front Brake Lines = bolt-in and long (can max out 12" shocks and still have slack)

Axles:

-Bolt-in Swap:

1.XJ C8.25 Rear ('97+) = bolt in and upgrades to 29 spline (strength comparable to D44)
2.XJ D44 Rear = found in some but not all '87-'89 XJ's with Towing Package
3.XJ D30 Front = ('95-'99) non-disconnect, larger u-joints, high pinion
4.XJ I-4 & some V6 = may have 3.73, 4.10, or 4.56 gears may have vacuum discos
-Moderate Fab to Fit:

1.Ford 8.8 inch Rear ('97+) = need spring & shock mounts (3.55, 3.73, or 4.10, maybe LSD, Disc Brakes)
2.MJ D44 Rear = need new spring perches and shock mounts
3.MJ AMC 20 Rear = need spring perches and shock mounts
4.Ford HP44/9" Combo = full width, more intense fab
-Misc:

1.Lincoln Lockers = welded spider gears, operates like a spool, must be a GOOD welder
2.G80 LSD locker from '90s Turbo Volvo with D30 rear for XJ front D30 (beware with larger tires)
3.Homebrew posi-locks for '84-90 vacuum disconnect D30s, eliminates vacuum actuation

Steering:

1.ZJ V8 Tierods = beefier & bolt in
2.WJ Knuckles/Tierods/Draglinks = beefier and crossover steering
3.Durango Steering Box = beefier
4.GM 2wd fullsize truck steering box = beefy, helps for wb stretch
5.Astro Van steering box = good for long wb stretch
6.ZJ pitman arm = 1 inch drop over stock
7.WJ power steering pump (fits '96+, plug return hole, and use XJ pulley)


Engine:

-Performance:

1.Newer XJ intakes (may require some modification)
2.Mustang 5.0 Injectors = near bolt in (have 4 holes instead of 1, more fuel, better spray)
3.Dodge Neon Injectors = better throttle response
-Alternator:

1.Mopar 136Amp Alternator, bolt it (slight grinding required) found in: 97-98 Dodge Full Size Van, 97-1998 Dodge Dakota, 97-98 Dodge Durango, 97-98 Dodge Ram, 97-98 Jeep Grand Cherokee
2. Dakota (2.5L I-4) Alternator = bolt in, upgrades to 117A
-Cooling:

1.Ford Electric Fan ('90-95 3.8L Taurus, '87-93 5.0L Mustang) = replaces mechanical fan, more cooling (8C607)
2.Hoodvents (i.e. Lebaron, Laser, Turbo Thunderbird etc.) = help keep ur 4.0 cool at low speeds
3.You can convert the closed system to open without replacing your radiator by using the fill cap from a 4.7 durango or dakota, cutting it into your upper hose, and replace your bottle with an MJ overflow tank or any that fit. Then cap off or eliminate the T'ed lines in the heater core.
-Swaps:

1.For '84-'86 XJ with 2.8L GM V6 only! you can swap in any 60* GM V6 engine, they use the same motor mounts and bellhousings, engine options include 3.1L, and 3.4L etc, but DOES NOT INCLUDE 90* GM V6 engines such as the 4.3L!!! this swap will allow you to gain horsepower, torque, and fuel injection

Transmission:

1.ZJ and WJ stock tranny coolers with stacked plates (even an upgrade for us with the stock fin style)
2.'94+ V6 Dakota AX-15 = bolt in (but must use XJ bellhousing), good upgrade from AX-5

Transfer Case:

1.'89+ AX-15 5spd crossmembers give 3/4 inch t-case drop on autos with no loss in ground clearance
2.Homebrew Slip Yoke Eliminator (use search function)
3.NV241-OR (from TJ Rubicon only) = near bolt in, 4:1 low range
4.Doubler Options : NP231/NP231, NP231/D300

Body/Exterior/Armor:

1.XJ '97+ doors onto older cherokees = one piece windows and better mirrors
2.’97+ mirrors are direct bolt in to older XJ's and allow you to fold them in on tight trails.
3.GM power antennas replace your broken XJ's with little modification
4.'96-00 Ford Explorer hatch shocks = lift your hatch about 3" lower but are beef (ever see one that doesn't work?) need modification for '97+
5.TJ Fender Flares (front and rear or rear all the way around)
6.Wheels from XJ, ZJ, TJ, YJ, Explorer, Magnum Steelies (17x7) (any with 5x4.5 bolt pattern) will fit....CJ, WJ, WK, KK, JK, Full-Size Ford 5 bolt rims will NOT fit
7.OEM swing-out tire carriers, get the bumper with it, found mainly on '84-'90 XJ's
8.ZJ skid plates = require slight modification, but can be made to work
9.OEM skid plates (Front, Tranny, T-case, gas tank, found on "up-country" package XJ's not the same as a Country Edition)


Interior:

1.MJ/2 Door XJ Bucket seats = tilt forward, near bolt in
2.XJ overhead console = most commonly found in '00-01 or higher trim level, provides space for switches etc.
3.'97+ center console = can be made to fit '96 and older, gives you cupholders
4.Grand Cherokee center console lid = sits higher, but gives rear passengers cupholders


*view following posts for more details.....and feel free to ask questions and as always....SEARCH!!!

**Also Blazin Den has made a list of links to build threads for us! Recap with Links!

JF Edition

*** PM ME IF YOU HAVE LINKS TO BUILDS FOR ANY MODIFICATIONS AND I'LL UPDATE THE LIST

Mods,
please do not make this a sticky....i want to be able to update the list as necessary....I'm sure we can keep it bumped to the top

Last edited by RedZeppelinXJ; 04-04-2011 at 09:24 PM.
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Old 04-03-2011, 06:53 PM
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Old 04-03-2011, 09:24 PM
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Good list.
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Old 04-04-2011, 02:19 PM
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Would WJ V8 coils work to lift the front of my xj and if so how much? Thanks
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Old 04-04-2011, 03:36 PM
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add this to the brakeline list.

2011 JK front brake lines
they are much longer than factory XJ lines, and the bolt right in.

here are mine, this is with my 12" travel shocks maxed out, and the brake line still has plenty of legth in it
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Old 04-04-2011, 09:07 PM
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N20jeep added the JK brakelines to the list
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Old 04-05-2011, 10:29 PM
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Old 04-08-2011, 04:26 AM
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Default WJ LCAs

My beef with the WJ LCAs is that they don't work for anything that's lifted. To elaborate; I lifted my '87 XJ with a junkyard bastard setup, got about 3.5" lift. I had my XJ LCAs cut, angled, and boxed after. Smoothest ride I've ever had in a Jeep, and allowed for some mad flexing. Couple years later, get in a wreck, have to swap LCAs. Went with the WJ arms only to find out that they rest against the shock mounts on the axle, and leave no room for flex. Poor Jeep now bump-steers with every uneven surface in the road, and it seems like it's trying to make you throw up whatever you ate last.
So, WJ LCAs are most likely great if all you want is bigger tires, but tossing them into a rig with a lift doesn't seem to benefit anything.
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Old 04-14-2011, 01:22 AM
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Old 04-14-2011, 09:41 AM
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Question: for the rear fullsize GM shackles...Im pretty sure 88-98 is all the same shackles. I had a 1992, 1998 chevy and they were the same shackles. Not 100% if it makes a dif when put on a jeep...just wondering if this is right?
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Old 04-14-2011, 01:02 PM
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On the dakota leaf packs...93's would work, correct? Or no?
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Old 04-14-2011, 02:00 PM
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I've read that '97-'04 F-150's front shocks work on XJ front and are 3.1"s fully compressed & 6.4"s at full extension...can any verify this?
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Old 04-14-2011, 02:02 PM
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Originally Posted by 95whiteXJ
I've read that '97-'04 F-150's front shocks work on XJ front and are 3.1"s fully compressed & 6.4"s at full extension...can any verify this?
Correction...3.8"s longer fully compressed & 6.3"s at full extension
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Old 04-14-2011, 08:22 PM
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Question injector question need help

so what injectors would fit a 95 xj sport 4.0 HO??? been looking for days... would neon ones work for it everything's oem
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Old 04-14-2011, 08:44 PM
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Originally Posted by cwilliams469
so what injectors would fit a 95 xj sport 4.0 HO??? been looking for days... would neon ones work for it everything's oem
Dodge neon 703's...mine came of out 2 different '95s
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