On my 99 xj 4.0 auto.
We started on the rear figuring the rusted bolts there would be the worst. We were right!
Issues started right away with a snapped lug nut just taking the wheels off. Took a half hour to drill it out but luckily went very easy. You wouldn't believe how centered I was able to drill it.
Axle dropped fine from the u bolts with impact. Then it was time for the front leaf bolts..evil little bastards. They were stuck in the sleeve and wouldn't budge. So we broke out the "EARTHQUAKE" 1 inch impact. This thing seriously sounds like a full auto assault rifle. And guess what..still didn't move. We figured it was gona either come out or break. Come out the torch. Cut the leaf off then the eyelet. Got the half molten bushing cut out put some heat on the sleeve not on the seam but next to it. Put the earthquake on it again and came right out. Other side went the same.
Had to heat shackle end leaf nut came out with the earthquake. Cleaned up and installed new leafs had to make new center pins long enough to use the 3* shims. Re leaf pack pins weren't long enough. Used 3/8" grade 8 bolts and ground them round to fit into leaf perch.
Bolted everything back together. At this point removed the shocks completely and broke two upper bolts and one lower mount bolt.
Today we will be fitting brake line extention and new shocks. And move to the front.
Hopefully it goes a little smoother. Wish me luck

 

Sounds like everything broke that could break.

I've been spraying blaster all over my bolts for the last three days in hopes of something loosening up without problems when I do mine.

Although I have never used a penetrating oil that actually penetrated into the threads past the rust.

 

This is probably going to turn into a build thread.
Got into the brake line extention last night. even after a couple days soaking in pb blaster the line nuts were still seized. Which didnt matter anyhow the main line broke like nothing. Better in th garage than while on the road. Ran a new line from booster all the way back. Previous owner had the short lines going to the wheel cylinders replaced at some point and are still in good shape.
Bled brakes no leaks, called it a night. mounting rear shocs today and hopefully starting front end. Gona take the camera and start getting some pics up here

 

Pics are good.

good luck.

 

Good luck with the lift, I am also rockin the 3.5 kit. And ran into almost every problem you have had so far. My story even includes 5 stitches from the breaker bar letting loose when trying to get at those front leaf bolts.. The front goes alot easier... usually.. lol.

EDIT: and I installed RC brake line relocation brackets.. before I got into the rear line.. i looked at it and was like.. yeah thats gonna break.. so I also had to do as you... from the booster back. I got 4 inches longer though so it wasnt so tight getting to the bracket.. i need to do an actual longer line though, next year im planning on that.

 

Make sure you have these supplies tomorrow:

Beer
Big hammer
Punch
new grade five bolts and nuts for the rears shocks
fishing line
band aids

 

Fixed

 

I always laugh at my luck compared to everyone else on here with cherokees as new as 98. My 89 that has probably never even seen new windshield wipers sense leaving the lot (before me buying it that is) did not break a single bolt or have a single problem when i did my lift. lol. I just PB blasted for 3 days like everyone else and didnt have any problem.

 

Went through two 12 packs when me and a buddy did my lift.

 

Shut up. LOL.

 

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

By nbock951 at 2011-10-26

 

I had a good write up on all I did so far but my session apparently timed out and I lost it all.
Anyhow, when it was all said and done. My only issue of the final outcome of the rear was that my shocks are about 1 inch short when the vehicle is unsprung. This wont be an issue 99 percent of the time. But when flexing, one side may and most likely often will go unsprung putting all the weight and stress on that one shock and mount. Aside from buying different shocks for this small problem what else could I do. I thought limiting straps?

 

Wow. What brand is your 1" impact? If it couldn't break that bolt that's pretty sad.

 

its this one

 

Not sure what that its but I've used 1/2" impacts that could snap that bolt. Let alone the 2000 ft lbs of torque the 1" impacts I used had.