1991 Jeep Cherokee XJ Unlimited Buildup - From "J_ep" To Jeep

We haven't tried the Daystar 1000 series lights yet, but if they're like other Daystar products they'll return great performance at a low cost. Daystar also offers a switched wiring harness to make installation that much simpler.

Desolate Motorsports in Whittier, California, is a small shop that delivers big-time. You've seen Desolate's work in 4WD&SU before: Desolate built the front bumper for the 4Runner Unlimited. Greg Gilbert, Matt Carter, and Danny McKenna took the divide-and-conquer approach to the XJ. Greg worked on the transfer case, while Carter (Matt goes by his last name at the shop) and Danny double-teamed the suspension. The author jumped back and forth between these operations, snapping pics rapid-fire style. Once on the lift, the XJ yielded up all but one of its stock wheels. The left rear was rusted onto the axle shaft. Carter started the persuasion process with a urethane mallet and penetrating oil.

The oil and mallet combo wasn't convincing enough, so the gas wrench was next. After a lot of heat and some hard knocks with a lead mallet, the wheel finally gave way. Did we mention that Utah's salty winter roads wreak havoc on running gear? If there was ever an excuse to upgrade to aluminum wheels, this is it.

With all four wheels removed, the axles were supported on stands and the drag link and track bar were disconnected. We’ll concentrate on the suspension, rolling stock, and SYE kit this time, and detail the bumpers, winch, and lights next time. We wouldn't do justice to the upgrades if we crammed them all into this month's story.

The stock coils were set aside and replaced with the Skyjacker lift coils.

If your XJ has a coil retaining clip, use it.

The front shocks mount to the stock locations using the stock methods.

The shocks arrived with empty eyelets. Danny McKenna used a vise and some grease to install the urethane sleeves and bar pins in the shock eyelets. Simple.

The shocks' upper mounts were easier to reach using a long extension. Air tools made the job less labor-intensive. Could this suspension system be installed at home in a driveway? Yes, but we'd advise setting aside a complete weekend instead of a single afternoon.

Skyjacker's extended sway bar links bolt to the stock locations, but feature a quick-disconnect center section that enables superior flex on the trail.

The track bar re-location bracket bolts into the stock axle-end track bar bracket. The track bar will be hooked up later after the "J_ep"-turned-Jeep is back on the ground.

Compare the Skyjacker lower control arms with the stock lower control arms and it's obvious the two come from different worlds. Heavy-wall construction, adjustability, high mobility, and greaseability are all hallmarks of the Skyjacker lower control arms.

The lower control arms' length is set and locked in per the provided instructions. Grease is used during assembly, and the grease zerk fittings are then installed on the arms. The lower links are replaced one side at a time.

The caster adjusters were backed off all the way before the new lower control arms were installed. We'll visit an alignment rack after the suspension installation is complete.

Re-installing bolts can be a pain. To make it easier, a tapered rod was inserted through the bolt hole and used to align the control arm with the bracket. With the mounting bracket and the control arm aligned, the bolt was then tapped through the other end using a non-marking brass-faced hammer. Several stock mounting bolts are used when installing this suspension system. If any of your stock bolts are damaged be sure to replace them.

Skyjacker did its homework, so the steering damper bolts into...

...the stock mounts without modification.

The rear suspension was by far the most rusted and tough to work on. The front end had had the dubious benefit of a leaky engine which coated many surfaces with oil. It was messy, but at least it wasn't rusted! We blasted the underside of the XJ at the coin-operated car wash before we brought the "J_ep" to Greg and the crew.