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1991 Jeep Cherokee Build

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Old Apr 2, 2026 | 08:37 PM
  #91  
Green93XJ's Avatar
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
Default Lower Shift Boot Replaced

So my lower shift boot has been all but missing since I got this thing. Was given a regular boot from a 2007-2010 Wrangler and sunk some self tappers into it and so far it works wonderfully. The cab is a bit quieter now and there shouldn't be as much heat emanating from the center console.

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Old Apr 6, 2026 | 12:09 PM
  #92  
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It looks like you're missing the seal that goes around the shift lever and seals to the shift tower. I'd get that replaced as soon as you can, as it's an easy way for dirt to get in your transmission.

I swear, that tunnel cover plate looks like it takes the round TJ style shift boot. I'll be pretty mad at Chrysler if they made a few year specific shift boot for no good reason at all.
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Old Apr 7, 2026 | 11:53 PM
  #93  
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
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Originally Posted by OptionXIII
It looks like you're missing the seal that goes around the shift lever and seals to the shift tower. I'd get that replaced as soon as you can, as it's an easy way for dirt to get in your transmission.

I swear, that tunnel cover plate looks like it takes the round TJ style shift boot. I'll be pretty mad at Chrysler if they made a few year specific shift boot for no good reason at all.
Oh for sure I plan on getting one ASAP especially since I go to Moab every year. Glad they still sell em on Amazon
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Old Apr 7, 2026 | 11:56 PM
  #94  
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
Default Replaced Main Vacuum Hard Line

After dealing with my hard line breaking apart over time, I finally replaced the whole thing with a tough silicon "soft" line. Found a 10ft set on Amazon along with a 155 piece coupler kit to plumb my vacuum gauge in-line along with some other things. Works fine if not better and I can route it however I want. Just need to get a check valve now.



10ft Line:
https://www.amazon.com/dp/B0CM1F1X7R?ref_=ppx_hzod_title_mob_b_fed_asin_titl e_0_0

Couplers:
https://www.amazon.com/gp/aw/d/B0BVVY9KQF?psc=1&ref=ppx_pop_mob_b_asin_title
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Old May 7, 2026 | 11:13 PM
  #95  
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
Default Driver Door Hinge Pins Replaced

Today I installed 97+ hinge pins and man is it nice having a door I dont have to slam shut. Even made use of the copper bushings that came in the kit and there is absolutely no play.


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Old May 23, 2026 | 10:09 AM
  #96  
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
Default 3.55 Rear Axle installation

Ever since I got this Cherokee, it has had 3.07 gears which are annoyingly slow on the highway. And now that I live in Colorado, the hills are just eating fuel economy so when I came down to Texas to get some things, I visited my junkyard and pulled a Chrysler 8.25 from a 2001 and put it in mine. The only issue now is my driveshaft is an inch too long and will bottom out on the transfer case if I hit a bump too hard. Going back today to find another from an auto 4wd cherokee with a dana 35. Should be short enough to use. Plan on getting a front axle with 3.55s soon.

Dana 35
Dana 35
Chrysler 8.25
Chrysler 8.25

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Old May 23, 2026 | 02:27 PM
  #97  
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Originally Posted by Green93XJ
Going back today to find another from an auto 4wd cherokee with a dana 35. Should be short enough to use. Plan on getting a front axle with 3.55s soon.
That's the driveshaft I'm using for my AX15/NP242/C82.5 driveline combo. It's 1/4" shorter than the factory spec. I'm not sure if you have an internal or external spline t-case, but the theory should carry over between the two styles.

3.55 FDR is great with a 30-31" tire. I'm very happy with the results having manual swapped my XJ.

If you want to get a beefier diff cover on the 8.25 for cheap while you're at the junkyard, go look under 2nd gen Dodge Durango/Chrysler Aspens. The rear suspension used a Watts linkage to locate the axle from side to side, and it has a thick cast iron diff cover with a slightly higher fill plug. Make sure you get one from an 8.25, as they also used the 9.25 axle. And grab the diff cover bolts at the same time, they are longer.


Last edited by OptionXIII; May 23, 2026 at 02:32 PM.
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Old May 23, 2026 | 08:24 PM
  #98  
Green93XJ's Avatar
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From: Colorado
Year: 1991
Model: Cherokee (XJ)
Engine: 4.0L
Default

Originally Posted by OptionXIII
That's the driveshaft I'm using for my AX15/NP242/C82.5 driveline combo. It's 1/4" shorter than the factory spec. I'm not sure if you have an internal or external spline t-case, but the theory should carry over between the two styles.

3.55 FDR is great with a 30-31" tire. I'm very happy with the results having manual swapped my XJ.

If you want to get a beefier diff cover on the 8.25 for cheap while you're at the junkyard, go look under 2nd gen Dodge Durango/Chrysler Aspens. The rear suspension used a Watts linkage to locate the axle from side to side, and it has a thick cast iron diff cover with a slightly higher fill plug. Make sure you get one from an 8.25, as they also used the 9.25 axle. And grab the diff cover bolts at the same time, they are longer.

Its interesting because the driveshaft I pulled out was like an inch shorter with not a lot of spline engagement. Luckily there was a 4wd manual cherokee with an 8.25 with its driveshaft so I just took that. Had to swap the yoke over along with new u-joints because it was rusted and someone stuck it directly in the mud.
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