Many years ago, we featured Chad Hughes' XJ Cherokee in 4WD&SU Magazine. It wasn't the biggest or most modified XJ, but it was maybe one of the finest examples of attention to details that made it work well everywhere. Chad did it again, this time to his 1999 TJ Wrangler that he purchased with less than 7,000 miles on the odometer in 1999.
Chad immediately went to work on his Jeep, installing numerous suspension systems, 35-inch tires, and a Detroit Locker in the stock Dana 44 rearend. Chad wanted more. When it was introduced, he purchased Rubicon Express' new TJ radius long arm suspension. This was the original RE suspension that used radius arms up front and a four-link in back. He reported that this system worked well, but he didn't like the way his TJ lifted the left front and squatted in the rear on steep climbs.
Chad's XJ, which had coils up front and leaf springs in the rear, worked well. Why not set the TJ up this way and, instead of using steel leaf packs, use fiberglass? Fiberglass leafs had been used on other vehicles, such as the Corvette and GM Astro and Safari vans. The Astro leafs were, in fact, what Chad had in mind. He went to his friendly salvage yard and found a few sets of Astro rear leaf springs.
GenRight Off-Road had by this time entered the scene with their fine aluminum gas tanks and other products. Chad figured that he could stretch his TJ's wheelbase by using GenRight's gas tank and would only need about 4 inches of lift to clear 37-inch tires if he used Poison Spyder's front tube fenders and fabricated his own rear fenders. He also had other ideas to make his TJ special.
We'll show you those ideas in the photos. This is an amazing TJ. The fiberglass leafs in back ride well and, with their inherent damping, controlled. It just goes to show how attention to detail can make all the difference.
 Jeep's 4.0L six is a great...  Jeep's 4.0L six is a great engine in stock form. Chad improved it by installing an Edge throttle body on a Hesco throttle body spacer breathing through a K&N cold air intake. Torque tube headers scavenge the exhaust. Flex-A-Lite's 3300 cfm electric fan helps the mill keep its cool. Currie motor mounts raise the engine 1 inch, allowing a better rear driveline angle. An Optima Yellow Top sealed battery doesn't leak and a Quick Air 3 compressor supplies air for the ARB and inflating tires. Behind the engine, a Jeep 32RH three-speed automatic tranny sports a deep Currie pan and is cooled by a large RV cooler. |  At one time, Currie Enterprises...  At one time, Currie Enterprises was able to procure Venezuelan Jeep high-pinion Dana 44 frontends and sold them as bolt-in solutions for TJ Wranglers. Chad bought one and installed 4.88 gears and an ARB Air Locker. Currie’s steering box brace and adjustable track bar were also installed. Chad gusseted the Cs, even though knuckle weakness wasn't an issue like it is on the JK Wrangler 44. The Currie CurrectLink steering system includes the tie rod, drag link and is very strong. Bent TJ drag links are no more. Superior chromoly inner and outer axle shafts further strengthen the 44. The loop welded to the bottom of the tube is a tie down point for when the TJ's being trailered. |  Gen Right hood louvers really...  Gen Right hood louvers really work to dispel underhood heat. |
 Rubicon Express radius arms...  Rubicon Express radius arms have been modified to stretch the wheelbase. |  Chad did a spring-over conversion,...  Chad did a spring-over conversion, using an 8-inch Tuff Stuff spring pad and U-bolts out of a Ford Ranger. With the torque bar and inherent damping of the fiberglass leafs, there is absolutely NO axle wrap. |  Here's a close-up of how the...  Here's a close-up of how the spring eyes attach to the fiberglass leafs. |
 A Teraflex Belly Up skidplate...  A Teraflex Belly Up skidplate is flat and much higher than the stock crossmember. There are also custom engine oil and transmission pan skidplates. The TJ's stock NP231 transfer case was beefed up with a heavy-duty chain and slip-yoke eliminator. Note how Chad designed the front torque bar mount (to the left of the transfer case). |  The homemade torque bar attaches...  The homemade torque bar attaches to the top and bottom of the rear axle tube. Tom Wood's Custom Driveshafts built the front and rear CV driveshafts. |  Gen Right's aluminum tank...  Gen Right's aluminum tank allowed the axle to be moved back 4.5 inches. This, added to the front stretch, gives the TJ a 99-inch wheelbase. The rear bumper is from Currie Enterprises. Chad flush-mounted the OE taillights. While the suspension isn't too crossed up here, you can see how the Johnny Joints allow the leaf springs to move. A number of rear shocks have been tried, but the ones that work the best are original equipment JK Rubicon gas shocks. Mopar has a tendency to be light on rebound damping, but the JK shocks work perfectly with the fiberglass leaf springs. |
 The interior is still OE TJ...  The interior is still OE TJ Wrangler, although Chad coated the tub with Line-X so it could easily be hosed out. |  Currie Enterprises was sourced...  Currie Enterprises was sourced for the front bumper and tow bar mounts you see underneath. The trusty Warn XD9000i has a control switch wired in the dash. The plug you can see is for when the vehicle is flat-towed. |  Bestop soft half doors can...  Bestop soft half doors can be easily removed and stored. Currie Enterprises rocker guards protect the sides. |