Jeep Cherokee XJ Pre Runner / Trail Off Road Build on 35″s
- Class: Prerunner / Trail Rig
- Off-road Capability Score: 70/70
- Complexity Level: Pro
With it’s boxy design and impressive modification potential, the Jeep Cherokee XJ remains one of the most favorite platforms among the fans of off-roading. Having a huge aftermarekt support which offers everything one could possibly ask for, and massive collective knowledge about modifications accumulated on various forums and FB groups, the XJ Cherokee indeed is a perfect choice for a DIY garage build.
This particular example of a 1997 Jeep Cherokee XJ has been extensively modified by it’s owner from Bend, Oregon to be an ultimate Do-it-All off-road rig, which he meticulously put together piece-by-piece in his garage, without overlooking any component.
Owner’s Input
– It was my goal to build the best allrounder Trial/pre-runner that we could take to Moab or prerun in Baja and its pretty dam close to that. Can be towed behind your motor home or driven anywhere. It eats bumps like butter and is super comfortable.
It was my goal to build the best allrounder Trial/pre-runner that we could take to Moab or prerun in Baja and its pretty dam close to that.
– I searched for ever to find a super clean stock unmolested starter and proceeded to dig in lol. This Jeep has had every bolt and nut touched (most replaced with higher grade, torqued and markeled). We tried to use all US made products when we could.
While being considered as a budget vehicle platform, compared to newer 4x4s, this Chevrokee build can not be called “Budget” in any sense, because the owner spared no expenses in the process of choosing the parts for it, giving preference to quality American-made components only. He didn’t leave any bolt or nut untouched, replacing every component with a higher grade alternative, prioritizing quality and durability over cost.
A trained eye will immediately notice extensive upgrades in the suspension and drive train departments behind the clean exterior. To fit into the concept of a universal prerunner / trail rig the owner had to completely reimagine the front and rear suspension setup, optimizing it serve both functions without compromises.
“The suspension system on this XJ is where true off-road mastery shines”.
The front suspension features an SFR 4 link long arm kit, custom track bar, Currie Anti Rock sway bars and FOX 2.5 internal bypass shocks + limit straps, bumped and locked at 11″ of travel. As for the springs, the owner decided to use a set of Rusty springs that provide approximately 5″ of lift which is just enough oversized 35″ tires.
The rear suspension setup provides 12″ of the wheel travel thanks to the installation of Hybrid Deaver springs, OME leaf pack ( to get the desired ride height and spring rate), Longer custom Shackle, FOX Shocks with remote Reservoir, Urethane progressive bump stops and other components. It has been meticulously adjusted to gain a ride height and spring rate that offers unmatched off-road performance.
Speaking of “off-road” – the 4×4 capabilities of this rig were bumped up with a help of a Dana 30 front and Explorer 8.8 rear axle conversions. These axles, bolstered with ARB and Auburn lockers respectively and sporting 4:88 gears, provide the necessary traction to navigate the trickiest corners of Moab trail. IronRock’s sturdy steering box mount and 1 TON SFR steering link kit allowed to get precision steering that’s also prone to the abuse of the trail.
Custom-fabricated bumpers feature an integrated 2″ hitch mount. Its aluminum skid plate and all DOM tube body ooze strength, while the JW Speaker LED headlights and Iron Man 7″ Blaster combo LEDs light up the path ahead.
List Parts & Mods
Engine
- 4.0L HO. Head has been gone through
- ARP head studs installed, head gasket
- Banks stainless header
- Complete custom stainless TOG welded exhaust with Dynamax muffler)
- Oil sending unit
- Injector heat shield
- SFR complete motor mount kit (upper and lower) thermostat
- All hoses replaced
- Aluminum radiator
- Custom battery box with yellow top series 34 battery
- Complete Jeep cables big kit
- Oil pan gasket and rear main seal.
Transmission
- T-case has Advance adapters slip yoke eliminator kit
- Azzy’s shift linkage and SFR rear trans mount
- Tom Woods double cardan drive shaft
Front Suspension
- SFR 4 link long arm kit
- Alloy links with Johnny Joints
- Frame side link mounts are bolted and welded in to the frame stiffeners
- Custom Track bar and mounts (on H&K rod ends) to achieve zero bump steer
- Rusty springs (approx 5″ of lift)
- Prothane spring inserts with Overtime fab works inner delrin solid bump limiter
- FOX 2.5 internal bypass shocks + limit straps (Bumped and strapped at 11″ of travel)
- Currie Anti Rock sway bar
- All Link mounts are skid plated and gusseted
Rear Suspension
- Hybrid Deaver springs
- OME leaf pack ( to get the ride height and spring rate we liked)
- Longer custom Shackle
- SFR Shackle relocator box
- FOX Shocks with Res
- Urethane progressive bump stops
- Rear is bumped at 12″ of travel
Front axle
- Dana 30 non actuated front high pinion
- Artec truss
- Synergy C’s gussets
- WJ knuckles
- 4 piston Akebono brake calipers with drilled/slotted rotors
- Timkin bearings.
- 4:88 gear
- ARB Locker
- U-joint cap kit
- Stainless brake lines.
Rear axle
- Explorer 8.8, 4:88 gear
- Auburn Truetrac
- Desolate truss
- Yukon super 88 kit
- Chromoly 31 spline axles drilled to 5 on 5.5 (big CJ or Ford pattern)
- C clip eliminator kit. Essentially the same as a 9″ design now
- Stainless brake lines.
Steering
- IronRock steel steering box mount
- Grade 8 bolts
- Custom Boost Works sector shaft support bearing integrated into the front bumper
- 1 TON SFR steering link kit (all solid Alloy with 1 TON Chevy ends)
- Wobble stops
- Tie rod is top mounted on the WJ knuckles to achieve zero bump steer
Wheels
- Set of five 35X12.5X15 BFG KM3 (c rated) with the center 6″ sipped for crazy grip
- Set of five 15×8 (5 on 5.5) American Racing wheels (NOS) from the late 90’s direct from Jim Conner racing. Had these on the shelf waiting for the right project for years
- All US made lugs
- Custom one-off low profile center caps
Bumpers
- Front is custom fabricated with integrated 2″ hitch mount (for winch or tow point), 1/4″ aluminum skid plate and all made of 1 3/4″ wall DOM (mig/tig welded). Sway bar protection so the bumper would hit first.
- Rear is a custom fabricated hitch/bumper combo using the stock skin over all DOM tube. Corners wrap around the Cut and folded corners and connect to the frame via tube connectors so the bumper corners could be used as a jack point. Custom mini rock/mud flaps.
Lighting
- JW speaker LED Headlights with a Colorado harness head light relay and harness kit
- All internal and external lights have been switched to LED
- Front had Iron man 7″ Blaster combo LEDs.
Exterior & Interior
- Complete front to rear frame stiffeners 3/16 and completely welded
- Everything has been painted with Steel-it from the frame stiffeners to the bumpers
- PRP steering wheel with GenRight Quick release
- 3M Ceramic tint
- Aero latch hood latches
- Dee Zee hood vents
- Hannaman glass fenders
- RC seat covers
Conclusion
This extensively modified 1997 Cherokee XJ belongs to some of the best examples ever put together on this platform. Based on our off-road capability rating system, it scores perfect 70 out of 70 points possible, thanks to the combination of 35″ BFG KM3 tires, front ARB and rear Auburn lockers, upgraded Dana 30 and Explorer 8.8 axles, and custom-fabricated bumpers.
The owner’s dedication to using premium American-made components, and top of the line solutions like the FOX internal bypass shocks, has resulted in a vehicle that’s equally capable of conquering technical Moab trails and pre-running in Baja.
This Cherokee build proves that with the right combination of parts, expertise, and attention to detail, these boxes on wheels can be transformed into some of the most capable and reliable 4×4 tools.
