FSJ Offroad Build: 1978 Jeep Cherokee Chief on 37s & 4″ Lift

If you’re a big fan of the vintage full-size Jeeps, this lifted 1978 Cherokee Chief equipped with legit off-road upgrades will serve as a perfect inspiration source and provide an ideal blueprint for a truly capable off-road build.

Featuring the unmistakable wide grille familiar from the Wagoneer models and the elegant lines of the C-pillars, it’s safe to say that Chief’s design is aging incredibly well. Underneath the neat-looking body lies the good old frame and 4×4 drivetrain designed to take the real beating off-road. Perhaps it’s one of the reasons why this FSJ platform keeps attracting 4×4 enthusiasts even today. We spoke with it’s owner Ryan Harrod about the mods and upgrades he did to transform this good loocking rust bucket into a proper trail rig. Read on!

Key details:

At the base of this Jeep Cherokee Chief off-road build is the 4-inch suspension lift kit that significantly bumps the ground clearance and frees up the space in the wheel wells for massive 37-inch all-terrain tires.

Best Mod	The H1 wheel / 1-ton axle combo keeps the track width manageable.
Toughest Challenge	Fitting 37s on an SJ usually requires aggressive fender trimming, hence the custom tubes.
Ideal Terrain	Mud, deep ruts, and wide rock trails (too wide for tight forest switchbacks).

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List of Parts Used in this FSJ

Powertrain:

• 401 AMC V8 motor
• Rebuilt Turbo 400 transmission
• Shift kit

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Suspension Lift Kit and Drivetrain:

• Dana 60 front axle
• 14 bolt rear axle
• Twin stick Dana 300 transfer case
• San Diego Driveline driveshafts
• Full high steering
• 4 inch lift
• Longer travel shock mounts
• Deaver springs
• Shackle flip

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Wheels:

• 17-inch Hummer H1 wheels
• 37-inch military Wrangler M/T tires
• Trail Worthy Fab double beadlock inserts

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Other Mods:

• Custom tube fenders
• Custom tube bumpers
• Dual battery setup
• 24-volt welder

Off-road Build Details

Engine

A 401 cubic-inch AMC V8 motor under the hood of this vintage Cherokee Chief eats gas by the gallon, but in return provides plenty of low-end torque to maintain a slow but steady crawl over the obstacles on the trails. Its output is handled by the fully rebuilt Turbo 400 automatic transmission fitted with a shift kit for firmer, more responsive gear changes ideal for off-roading. With the robust drivetrain delivering tire-churning traction, this classic 4×4 Jeep has the grunt to conquer tough terrain and make short work of muddy trails or steep inclines.

4″ Lift Kit and Deaver Springs

An expert reader may know that a ’78 Cherokee SJ Chief “Wide Track” came from the factory with Dana 44s. Even though it’s quite a capable setup, the owner decided to step up a notch and swap it with the more durable Dana 60 front axle and 14-bolt rear axle from one-ton trucks.

As you can guess, it required quite a bit of time and effort as swapping to 1-ton axles requires cutting off the factory spring perches, welding on new ones at the correct width, and adapting the driveshaft yokes.

The four-wheel-drive system utilizes a twin stick Dana 300 transfer case and custom driveshafts from San Diego Driveline to divide torque effectively between both axles.

This twin-stick setup allows the driver to independently control the front and rear axles. This means they can disengage the rear axle and engage only the front, allowing for “front digs”, dragging the heavy front end around tight corners on narrow trails where a massive Cherokee would normally just get stuck.

Instead of achieving a 4-inch lift just by using stiff, highly arched leaf springs (which would ultimately ruin ride quality and the wheel travel), a shackle flip reverses the factory rear shackle mount. This provides lift using gravity while allowing the owner to run flatter, softer Deaver springs. As a result, this SJ gained massive articulation without compromising the ride.

37″ Wheels

The black rugged wheels in the arches aren’t modern Black Rhinos or Fuel rims. These are genuine 17-inch Hummer H1 wheels, and they are here for a reason. The H1 wheels have massive backspacing (the mounting face is pushed far to the outside). Custom builders often use them on 1-ton axle swaps to tuck the massive 1-ton axles back under the fenders so the SJ Cherokee doesn’t end up being illegally wide.

The rims are wrapped in 37-inch Wrangler M/T military-spec tires, so the momentum provided by the fully overhauled drivetrain is never wasted. Double beadlock rings from Trail Worthy Fab further enhance the driveability and safety when running low PSI by mechanically fastening the tires to the rims.

Off-road Mods

To accommodate the massive tires and maximize clearance, this Cherokee Chief has been outfitted with custom-fabricated tube fenders and bumpers, replacing the original bodywork for an aggressive off-road stance.

A dual battery setup powers both the vehicle and an on-board 24-volt welder for trailside repairs, enhancing self-sufficiency. While built to excel off-road with its robust capabilities, this Cherokee still sees street duty and use towing jet skis to the beach, retaining day-to-day drivability. Needless to say, this customized Chief is prepared for adventure, whether tackling tough trails or cruising down open highways in rugged style.

The Expert Verdict

Based on our off-road capability score this build this lifted FSJ Cherokee Chief scores maximum 70 out of 70 points, thanks to heavily oversized 37″ tires, lockable front and rear axles and steel body armor throughout.

Related Parts & Mods

– Inspired by this lifted Cherokee Chief and looking to build your own capable full-size Jeep? Our team has put together a list of products and accessories available online that may help you to achieve similar results:

Transmission Shift Kit

• TransGo SK400 Shift Kit – For GM TH400 / Turbo 400 automatic transmissions (1965 & up) *firmer, more responsive shifts ideal for off-road use

Tire Deflators

• JACO RapidFlow Tire Deflator with Gauge – 0-60 PSI rapid air-down tool, great for running low PSI on beadlocks
• AutoEC Adjustable Brass Tire Deflators (4-Pack) – Set-and-forget automatic deflators, budget-friendly option

Air Compressors

• VIAIR 400P Portable Air Compressor – 150 PSI, rated for tires up to 35″ *for true 37″ tires, step up to the VIAIR 440P

Dual Battery Setup

• Dual Battery Isolator Kit (12V, 140A VSR) – Complete wiring kit for running accessories or an on-board welder off a second battery

*Always verify product compatibility for your specific vehicle with a seller before purchase. Specs and fitment may vary by model, year, and trim level. We are not responsible for fitment or other issues that may arise from using the products listed above.