Overland XJ: Adventure On A Budget

Probably the most bang for your buck of any off-road vehicle available today is the four-door Jeep Cherokee XJ—especially for pure versatility.

The classic, boxy, station wagon body style is unmistakable, especially because there were nearly 3 million built around the globe over the vehicle’s 18-year life span from 1983-2001. Because of the long model life, high build volume, and the vehicle’s off-road prowess, there is huge aftermarket support for this vehicle today.

While these vehicles have proven their durability, you can also be confident that no matter where you travel you are sure to find readily available inexpensive replacement Jeep Cherokee XJ parts. Because of the age of the vehicle, they are also devoid of any computers, which makes them easy to work on whereever your adventures might take you.

“While these vehicles have proven their durability, you can also be confident that no matter where you travel you are sure to find readily available inexpensive replacement Jeep Cherokee parts.”

The XJ was the first non-military 4×4 with unibody construction, which paved the way for the small SUV and crossover craze we see today. Its stock 4.0L inline-six puts out 190 hp and 225 lb-ft of torque. While not known for its power, the Cherokee is relatively lightweight and has enough grunt to carry a load, while traversing tough off-road terrain. The AX-15 five-speed manual transmission provides the driver with the control needed to get the most out of the motor in all conditions.

Sub $500

Adam Schalow bought an unmodified red 1994 Jeep Cherokee 4-Door SE 4.0L I6-powered five-speed manual model off craigslist for $450, and built it into the overland adventuremobile you see here. Yep, this is a sub-$500 craigslist story.

The Jeep Cherokee came with a bad clutch and the common rust issues that these vehicles have a reputation for, but Schalow is a mechanic and was able to address those issues himself. The rust, a continual battle, was the major repair when purchased and quite the job, as it required welding in new floorboard patch panels from a donor XJ from the muffler all the way to the tailgate above the passenger side framerail.

The idea behind this build was to create a comfortable, capable, easy to fix and inexpensive to keep on the road overland vehicle that could be completely self-sufficient and off the grid for up to seven days.

At First Sight

Schalow’s passion for the Jeep Cherokee runs in the family, and started at an early age. His first experience with the XJ was at age 8 when his father brought home a brand-new 1991 Laredo model. He and his father loved it so much that when Schalow turned 16, with a fresh driver’s license in hand, his father bought him a 1992 Country model.

Schalow was so excited to have his own new Jeep Cherokee that he spent that first night sleeping in it, sprawled across the back seat while parked in the driveway. He built that vehicle into a well-equipped rock crawler, but sold it five years later, as his interests shifted toward the world of sports cars. Fast-forward to June 2015 when Schalow was on the hunt for a VW Westfalia Bus to enter the world of overland travel. While on the hunt for the bus, he came across the craigslist ad for this XJ, and it was love at first sight.

Cost Conscious

Everything on Schalow’s off-road vehicle build is done with cost and function in mind. Each dollar saved on the build is another dollar that can be spent searching for adventure on the road less traveled. Schalow stuck with the stock XJ wheels, both for their “utilitarian” looks and cost savings.

He was able to modify a $75 Amazon special snorkel to work with the stock airbox, and mounted two $20 LED Amazon light pods in the front bumper, which he sealed up with RTV for better moisture resistance. Sure these aren’t the highest performance or most durable products, but they get the job done, can be replaced easily and are incredibly inexpensive.

Schalow found a great used deal on a Rough Country 3-inch lift and three Nexen Roadian MT (31×10.5R15) tires, which only had 800 miles on them. The entire lift kit has since been upgraded to higher-quality parts, which offer up a much better ride.  He loves the tires off-road, but only gives them a 2.5 out of 5 star rating for on-road use, and says they are nearly impossible to balance properly on his wheels. Perhaps it’s his wheels or something the previous owner did to the tires, he can’t be sure.

Built For Function

The 4×4 capabilities of this XJ are improved with a few other key parts as well. The Rusty’s Front Bumper offers up a winch mount, which houses a Warn M-8000 with Rugged Ridge synthetic line and utilizes a Southeast Overland hawse fairlead. Its rear bumper is a custom-made unit, which utilizes a trailer ball hitch coupler to secure the spare tire swing out and lockable double jerrican holder.

The radiator was upgraded to a Mopar HD unit, to keep the XJ running cool in the 100-degree Virginia summer heat, where Schalow lives. The front axle is a stock D30 with a Lockright Locker, while the rear is a non C-clip D35 out of a 1986 XJ, with 4.10 gears and a Lockright Locker. Its brake lines were also extended at all four corners, to work with the 3-inch lift, and the headlights were upgraded to improve nighttime visibility. When the trail gets tough, Schalow can also disconnect the front sway bar to get maximum wheel articulation.

Living Quarters

Since this Jeep Grand Cherokee is Schalow’s home away from home, when he’s on the road chasing adventure, it has all the creature comforts that you’d expect around the house. Most of the interior camping systems are based around a custom-built wooden platform system that houses much of the equipment, and doubles as a sleeping platform.

At the rear of the vehicle is a full kitchen setup that has a 31-quart Dometic drawer–style fridge and a heavy-duty slide out that holds a propane Coleman grill and a stainless Houzer sink. Always keeping a cold drink within reach, a Dometic 10.5-quart freezer is installed between the front seats. Making that work was no small task, as the stock console needed to be removed, the stock E-brake hole was welded up and a foot pedal E-brake system out of a Jeep Comanche needed to be installed.

“While not known for its power, the Jeep Cherokee is relatively lightweight and has enough grunt to carry a load while traversing tough off road terrain.”

Just because it was built on a budget doesn’t mean that it’s devoid of some luxury Jeep accessories. This overland XJ even has a custom pressurized hot water shower system, which utilizes a 10.6-gallon Front Runner water tank, 1/2-inch PEX plumbing, 12V Shur-Flo RV water pump, a Duda Diesel heat exchanger, and a Phoenix exterior RV lockable shower box.

All the electrical needs are handled with a dual battery system, which utilizes one deep-cycle AGM battery and is charged through portable Overland Solar panels and a Blue Sea charge relay/battery isolator. A Blue Sea ST Blade fuse block is used to handle the power needs of all the vehicle’s accessories.

Atop Schalow’s XJ is a roof top tent (RTT) and awning, mounted to two Thule gutter mount crossbars. The RTT is a 1998 Camping Lab model that Schalow picked up used, which offers up a comfortable 3-inch foam mattress and an optional full annex, which is equally great to escape the weather and use as a shower room. The awning is a Foxwing unit by Oztent/Rhino Rack and offers 270 degrees of coverage around the vehicle.

Future Plans

Schalow has grandiose plans for both this build and the places it will take him. The next vehicle upgrade will be a new motor, as the current one has some internal noises, is showing signs of compression issues in one of the cylinders, and has the occasional puff of blue smoke.

Smaller upgrades for capability and ease of use will also be addressed, like adding rock, backup, and awning lighting. Schalow thinks big, and plans to tackle a full custom Westfalia-type pop-top roof on the XJ himself, which will allow him to still sleep up high on the vehicle while also allowing him to mount kayaks and mountain bikes to the roof.

“Everything on Schalow’s off-road vehicle build is done with cost and function in mind. Each dollar saved on the build is another dollar that can be spent searching for adventure on the road less traveled.”

For Schalow’s next overland XJ adventure, he is hoping to take a six- to eight-week trip from Virginia all the way to southern Baja and back. First heading west to Southern California then down the Baja peninsula before coming back via ferry to mainland Mexico and meandering back to the East Coast.

For more info on Schalow’s adventures in his Jeep Cherokee XJ be sure to follow him on Instagram @Overland_History. Besides fun photos of the XJ in interesting locations, you’ll also learn a ton about the history of the places Schalow visits.

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UPGRADES

1994 Jeep Cherokee

Wheels & Tires: Stock XJ wheels wrapped in 31×10.5R15 Nexen Roadian MTs

Running Gear: 4.10 Yukon Gear front and rear, Powertrax Lock-Right Lockers front and rear

Suspension: 3.5-inch Rubicon Express coil and leaf spring lift kit with adjustable Trackbar, Bilstein 5100 Series shocks

Under The Hood:  Mopar HD radiator, Duda 20-plate heat exchanger, Top Gear Automotive headlights with H4 bulb upgrade, Flowmaster 40 series after-cat exhaust

Armor: Rusty’s Front Trail bumper, custom rear bumper with tire and double jerrican holders

Off-Road Accessories: Warn M-8000, Rugged Ridge Synthetic winch line, Southeast Overland Hawse Fairlead, Rough Country sway bar disconnect, Nilights Floodlight Pods

Overland Accessories: Camping Lab RTT, Foxwing awning, Thule roof rack, Overland Solar 90-watt portable panels, AGM deep-cycle battery, Blue Sea Charge Relay, Blue Sea ST Blade fuse block, Custom 10.6-gallon Onboard Hot Water Shower System, Dometic 31-quart Drawer Fridge, Dometic 10.5-quart Console Freezer, custom sleeping platform/storage system, Coleman propane grill, Houzer stainless sink, Blue Ridge Overland Gear seat-mounted organizational system, Blue Ridge Overland Gear spare tire storage bag

This article originally ran in the July/August 2017 issue of Tread magazine.

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FREQUENTLY ASKED QUESTIONS

What were the later uses of the 4.0-liter engine after the Cherokee went out of production?

Later Uses of the 4.0-Liter Engine After the Cherokee Went Out of Production

After the Cherokee ceased production, the notable 4.0-liter engine found continued life in subsequent vehicle models. Its journey did not end with the Cherokee; it was incorporated into the TJ Wrangler, remaining a trusted component until 2006.

However, the transition wasn’t met without some discontent. When the 4.0-liter was eventually replaced by a less remarkable 3.8-liter V-6, many enthusiasts expressed their disappointment, lamenting the loss of a beloved engine that had earned its reputation for reliability and performance.

Key Points

• The 4.0-liter engine was utilized in the TJ Wrangler until 2006.
• It was replaced by a 3.8-liter V-6, which did not receive the same level of acclaim.
• Jeep fanatics mourned the end of the 4.0-liter era due to its esteemed performance and reliability.

This shift marked the end of an era for a powerhouse engine that had garnered respect and admiration from a dedicated community.

 

How did the Cherokee’s engine evolve to gain its current status?

The evolution of the Cherokee’s engine is a tale of transformation from modest beginnings to iconic status. Initially, when the vehicle appeared in 1984, it was powered by an engine that offered a mere 110 horsepower. While this might have been sufficient for the era, the powertrain left much to be desired for enthusiasts seeking robust performance.

Key Evolution Milestones:

1. 1987 Update: Introduced a 4.0-liter inline-six engine, significantly boosting horsepower to 173. This change transformed the Cherokee from a simple utility vehicle to a more powerful and versatile option suited for both daily driving and adventurous escapades.
2. Unibody Construction: Unlike its competitors with body-on-frame construction, the Cherokee incorporated a unibody design. This modernized the SUV and provided a more comfortable ride without compromising ruggedness.
3. Solid Axles: Despite the advanced unibody design, the Cherokee retained solid axles. This blend of old and new technology allowed it to maintain off-road capabilities while improving on-road driving dynamics.

Market Impact:

The combination of the upgraded engine and innovative construction techniques helped elevate the Cherokee’s status. It became an American SUV icon, appealing to mainstream consumers and off-road aficionados alike. This balance between accessibility and ruggedness ensured its lasting legacy as both a popular choice and a cult classic.

In essence, the transition from a modest 110-horsepower engine to a more potent 173-horsepower inline-six was pivotal. It redefined what the Cherokee could do, turning it into a symbol of American automotive ingenuity and adventure.

 

What performance did the Cherokee achieve in a 1990 comparison test?

In a 1990 comparison test, the Cherokee demonstrated impressive performance. Equipped with a 177-horsepower engine and four doors, the automatic variant outperformed all other contenders. It achieved a remarkable 0 to 60 mph acceleration in just 10.5 seconds, which was considered quite fast for that time.

 

How does the 4.0-liter engine compare to the engines available before 1987?

The 4.0-liter engine stands out as a major improvement compared to the engines available before 1987. Earlier models featured less powerful options: a 2.5-liter four-cylinder, a 2.8-liter V-6, and a 2.1-liter turbo-diesel.

Key differences include:

• Power: The 4.0-liter engine delivers a substantial boost in horsepower, with the high-output version reaching 190 horsepower by 1991. This is a significant upgrade from the less powerful engines of previous models.
• Torque: Known for its torque, the 4.0-liter engine offers better performance, especially in demanding driving conditions.
• Durability: The 4.0-liter engine is renowned for its durability and reliability, standing up to rigorous use far better than its predecessors.

In summary:The 4.0-liter engine not only provides more power and torque but also offers a robust and dependable option, making it a vastly superior choice compared to the engines available before 1987.

 

What are some essential reads and features related to cars and driving?

Must-Read Stories and Features for Car Enthusiasts

Highlighting Key Issues and Features

1. July/August 2024 Round-Up
   • Explore groundbreaking automotive innovations and insightful reviews on the latest releases.
2. Exceptional Programs
   • Dive into the hands-on experience offered by top car restoration programs, like the one at McPherson College.
3. March/April 2024 Edition
   • A comprehensive overview of emerging trends and technologies in the automotive industry.

Electric Vehicles and Technology

• Understanding EV Charging Levels
  • Get a detailed breakdown of the various levels of electric vehicle charging and what they mean for drivers.

Personal Stories and Experiences

• Project Cars by Elana Scherr
  • Follow the journey of car enthusiasts as they take on ambitious restoration and modification projects.
• Cybertruck vs. Silverado EV Debate
  • Opinions and discussions on the competitive landscape between popular electric truck models.

Lifestyle and Culture

• Becoming a Watch Aficionado
  • A personal tale of attempting to delve into the world of high-end watches and how that parallels the passion for cars.

Event Highlights

• Subiefest 2024 Recap
  • A look at the biggest moments and best showpieces from the annual gathering of Subaru enthusiasts.

Industry Insights

• Interview with Michelin’s Tire Expert
  • Gain professional insights into tire technology and its impact on performance and safety.

Performance Cars

• Lamborghini’s Hybrid V-8
  • An in-depth review of Lamborghini’s shift towards hybrid technology without compromising performance.

Editorial Perspectives

• Annual EV of the Year Contest
  • The Editor’s perspective on this year’s top electric vehicles, highlighting the best in innovation and design.

Keep these features on your radar to stay informed and entertained on all things related to cars and driving.

 

What model years are recommended for buying a Jeep Cherokee?

For those considering a Jeep Cherokee, the model years from 1997 to 2001 come highly recommended. These particular versions benefited from a sleek exterior update and featured enhanced, more modern interiors, making them a solid choice for buyers.

In summary, the best model years for a Jeep Cherokee are:

• 1997
• 1998
• 1999
• 2000
• 2001

Each of these years offers a refined design inside and out, providing a blend of style and functionality.

 

What are the performance specifications of the 2001 Jeep Cherokee Sport?

Performance Specifications of the 2001 Jeep Cherokee Sport

Engine and Weight

• Engine: 4.0-Liter Inline-6
• Horsepower: 190 hp
• Weight: 3607 lbs

Acceleration

• 0 to 60 mph: 8.4 seconds
• Quarter-Mile Time: 16.5 seconds at 83 mph
• 0 to 100 mph: 30.3 seconds

Top Speed and Braking

• Top Speed: 108 mph
• Braking Distance (70-0 mph): 190 feet

Note: Acceleration times follow a 3 mph rollout rule, reflecting testing standards from early 2001.

 

What factors should you consider when assessing the value of a Jeep Cherokee?

When assessing the value of a Jeep Cherokee, various factors come into play that can significantly impact the price.

1. Mileage and Condition

• High Mileage: Vehicles with 300,000 miles or more typically have lower values, often around $1,000.
• Low Mileage: Expect to pay over $30,000 for low-mileage, well-preserved examples.
• Condition: Most used Cherokees show signs of wear. A well-maintained, decent-condition Cherokee should be available for around $5,000.

2. Model Year

• Recommended Years: Consider models from 1997 to 2001. These years include an exterior refresh and more modern interiors, making them more appealing.

3. Configuration and Features

• Desirable Features: Look for a two-door model with a 4.0-liter engine and a five-speed manual transmission for a more engaging driving experience.

Additional Considerations

• Modifications: Unmodified Cherokees typically hold their value better.
• Market Trends: Prices can fluctuate based on demand and the availability of Cherokees in your area.

Properly evaluating these factors will help you determine a fair price for a Jeep Cherokee that meets your needs.

 

What are some examples of recent sales of Jeep Cherokees and their prices?

Recent Sales Examples of Jeep Cherokees and Their Prices

1. 1999 Sport (Two-Door, 4×4)

• Sale Date: July 2023
• Price: $27,000
• Mileage: 44,000 miles

2. 1998 Limited (4×4)

• Sale Date: August 2023
• Price: $6,200
• Mileage: 134,000 miles

3. 1990 Pioneer (4×4)

• Sale Date: August 2023
• Price: $9,800
• Mileage: 70,000 miles

All listings sourced from a reputable auction platform.

 

What are the characteristics of the 4.0-liter inline-six engine?

The stock 4.0L inline-six puts out 190 hp and 225 lb-ft of torque. While not known for its power, the Cherokee is relatively lightweight and has enough grunt to carry a load, while traversing tough off-road terrain.

To truly appreciate this engine, consider its notable history. Introduced in 1987, the 4.0-liter engine quickly became a defining feature of the Cherokee. Prior to its arrival, Cherokees were equipped with less impressive engines such as the AMC 2.5-liter four-cylinder, GM 2.8-liter V6, and even a Renault 2.1-liter turbo-diesel. These earlier engines often fell short in terms of power and reliability.

The high-output version of the 4.0-liter, debuting in 1991, boasts 190 horsepower, making it a significant upgrade from its predecessors. This engine isn’t just about raw power; it’s also renowned for its torque and durability. Described as torquey, the 4.0-liter engine provides strong low-end power, making it adept at handling both highway speeds and rugged terrains. Moreover, its reputation for being nearly indestructible ensures that it can withstand the test of time and demanding conditions.

In summary, while the Cherokee’s 4.0L inline-six may not be a powerhouse, its blend of historical significance, improved performance over earlier models, and robust durability make it a standout choice for off-road enthusiasts and daily drivers alike.

 

What price range can you expect for used Jeep Cherokees?

< Person>Adam Schalow bought an unmodified red 1994 Jeep Cherokee 4-Door SE 4.0L I6-powered five-speed manual model off Craigslist for $450, and built it into the overland adventuremobile you see here. Yep, this is a sub-$500 Craigslist story.

But what can you generally expect to pay for a used Jeep Cherokee? Prices are all over the place, ranging from $1,000 for high-mileage, trail-worn rigs to over $30,000 for low-mileage, pristine, unmodified examples. Most Cherokees on the market are far from pristine, and prices reflect that. On average, you can expect to spend around $5,000 for a decent one.

So, while < Person>Adam’s story is a remarkable find, it’s essential to know the broader market spectrum when hunting for your own Jeep Cherokee adventuremobile.

 

What are common problem areas in the Jeep Cherokee?

“The Jeep Cherokee came with a bad clutch and the common rust issues that these vehicles have a reputation for, but Schalow is a mechanic and was able to address those issues himself. The rust, a continual battle, was the major repair when purchased and quite the job, as it required welding in new floorboard patch panels from a donor XJ from the muffler all the way to the tailgate above the passenger side framerail.

However, rust and clutch problems aren’t the only concerns with the Cherokee. The part-time four-wheel-drive system’s vacuum-operated front-axle engagement can fail, leaving you stranded or worse. Additionally, the 4.0-liter engine’s rear main seal is notorious for developing leaks.

For models produced before 1997, the rear hatch was made of fiberglass, which is prone to cracking. Another significant issue arises from ill-advised modifications. Be cautious of Cherokees with suspension lifts and larger tires. Even a modest three-inch lift can alter the rear driveshaft angle enough to shear the U-joints, and the Cherokee’s light-duty axles aren’t built to handle oversized tires.

In summary, while the Cherokee is a robust vehicle, it has its share of common problem areas. Whether it’s dealing with rust or navigating the pitfalls of drivetrain and engine issues, being aware of these potential problems can save time and money in the long run.”

 

How did the owner address the steering and suspension issues post-lift installation?

After taking the newly lifted vehicle for a spin, a couple of steering and suspension issues became evident. First, the steering felt off, not as responsive as expected. Second, driving over large bumps occasionally triggered a minor wobble in the vehicle. Although these issues resolved quickly on their own, they were concerning.

To tackle these problems, the owner decided to install a few key components. An adjustable track bar was added to stabilize the front end and improve steering response. Additionally, a drop pitman arm was replaced to correct steering geometry issues caused by the lift. The installation proved challenging, even breaking two pitman arm pullers, so professional help was enlisted. At a truck shop, the pitman arm was swapped out efficiently using an impact wrench.

Lastly, to accommodate the suspension lift and ensure smooth handling over rough terrain, extended sway bar end links were installed. With these upgrades in place, the vehicle’s performance improved noticeably. It now steers and handles bumps with ease, marking the end of this particular upgrade journey.

 

What issues did the owner face with steering and stability after lifting the Jeep?

After lifting the Jeep, the owner encountered some complications with steering and stability. Firstly, the steering felt unstable, described as “wonky,” making it a challenge to control the vehicle confidently. Additionally, the Jeep experienced occasional wobbling after hitting large bumps, which, although it corrected itself quickly, made the driving experience unsettling.

To address these concerns, the owner decided to make some key adjustments. They installed an adjustable track bar to improve alignment and control, added a drop pitman arm to correct steering geometry, and replaced the sway bar end links with extended, quick-disconnect versions. The effort to replace the pitman arm was particularly challenging, requiring professional assistance after some initial struggles.

These modifications ultimately improved the Jeep’s handling, ensuring smoother rides and better control over uneven terrain. The journey to achieve this stability was a bit complex, but it led to significant improvements in the vehicle’s performance.

 

What considerations did the owner have about installing rock sliders on the Jeep?

When deciding whether to install rock sliders on the Jeep, the owner weighed a few key factors. Primarily, their off-roading activities focus more on general trail riding rather than intense rock crawling, which might not necessitate the added protection that rock sliders offer.

However, they also considered the additional benefits: rock sliders can enhance the vehicle’s frame rigidity, which could improve overall performance and safety on various terrains. While not a current priority, the potential advantages of a sturdier frame make the idea of installing rock sliders intriguing, leaving them open to the option in the future. Overall, the decision involves balancing the nature of their driving adventures with the practical benefits rock sliders provide.

 

What challenges did the owner encounter while installing a lift kit on the Jeep XJ?

Challenges Encountered Installing a Lift Kit on a Jeep XJ

Transforming a 16-year-old Jeep XJ with a lift kit and new tires can be a thrilling but daunting experience. The owner faced multiple challenges throughout the process, providing valuable lessons for anyone considering similar modifications.

Initial Setbacks

The journey began with extensive research on various lift kits, eventually deciding on a 3-inch lift to accommodate a specific tire size. The installation started smoothly but quickly took a turn when the upper rear shock bolts broke as they were being removed.

Although prepared for this common issue, the task of drilling out the broken bolts proved arduous. After successfully extracting the first bolt, the real trouble struck with the second one. The tap broke in the middle of the job, necessitating professional help. Frustrated and worn out from the struggle, the owner turned to a local mechanic to finish the installation.

Unexpected Ride Quality

Upon completion, the lift appeared higher than expected—nearing four inches—indicating the potential for larger tires. However, the initial drive revealed a joltingly stiff ride. Conversations with the lift kit company pointed to the upgraded shocks as the cause, prompting the owner to purchase different shocks to rectify the issue. The replacement made a dramatic difference, highlighting how critical proper shock absorbers are to ride quality.

Additional Adjustments

With the new height, the Jeep exhibited some steering instability and occasional wobbling over bumps. To address these issues, the owner installed an adjustable track bar, a new pitman arm, and extended sway bar end links. While the installation of the pitman arm turned out to be particularly challenging—requiring several hours and breaking tools—it was eventually resolved by professionals in minutes with specialized equipment.

The Final Outcome

After tackling a series of roadblocks, from broken bolts to unwieldy handling, the owner successfully enhanced the Jeep’s capabilities and aesthetics. The process was indeed a journey filled with unexpected hurdles and learning opportunities, culminating in a smoother, more stable ride, and paving the way for further modifications.

 

How did the owner relocate the spare tire to free up cargo space?

How the Owner Relocated the Spare Tire to Free Up Cargo Space

The owner embarked on a project to remove the spare tire from the cargo area to increase space and prepare for a future drawer system installation. This process began with research into suitable rear bumpers with integrated tire carriers. After considering numerous recommendations, they decided on a product known for its robust construction and reliable performance.

Steps Taken:

1. Removing the Spare Tire:
   • The existing setup was dismantled, making room for additional cargo. This initial step was straightforward, though it required removing some components like the mud flaps, which couldn’t be reattached due to incompatibility with the new bumper design.
2. Installing New Bumper and Tire Carrier:
   • The chosen bumper, equipped with a tire carrier, was installed at the rear of the vehicle. Despite a slight gap in alignment, once everything was in place, the gap was barely noticeable, and the result was a solid, well-fit assembly.
3. Addressing the License Plate Issue:
   • One challenge encountered was that the new setup obstructed the license plate. To resolve this, the owner had to drill holes in the vehicle’s hatch to relocate and illuminate the plate. This involved installing an LED strip, connected to the existing license plate light wiring, ensuring compliance with vehicle regulations.

Through these modifications, the owner successfully relocated the spare tire, opening up valuable cargo space and preparing for future customization while maintaining functionality and legal compliance.

 

How did the owner resolve issues with the initial lift kit installation?

Resolving Issues with the Initial Lift Kit Installation

The journey of installing a lift kit on the Jeep was far from smooth. Initially, challenges arose while dealing with the rear shock mounts. After breaking a tap off in the drilled hole during the thread installation, the owner had to drive the Jeep without rear shocks to a local truck accessories mechanic. Although this resolved the issue temporarily, it took a week for completion.

Upon getting the Jeep back, it was clear that the lift was larger than anticipated—about 4 inches, instead of the expected 3. Though the new height allowed upsizing to 31-inch tires, the ride quality became a concern. It was extremely stiff, leading to discomfort during drives.

Initially, the owner reached out to the lift kit manufacturer, but with little assistance offered, a different solution was sought. Upgrading to a set of Old Man Emu shocks proved to be an effective move. The installation required minor adjustments, such as filing the bolts to fit, but once installed, the difference was significant. The ride improved drastically, revealing that one of the earlier shocks was defective.

Even with a smoother ride, the Jeep’s handling still had issues. The steering was unstable at times, and a noticeable wobble occurred after hitting large bumps. To address these concerns, the owner opted for an adjustable track bar, a drop pitman arm, and extended sway bar end links. While the pitman arm installation was challenging, requiring professional help, the truck shop resolved it swiftly using an impact wrench and puller.

After these upgrades, the Jeep operated smoothly with better steering and improved handling over bumps. This marked the conclusion of the complex journey to resolve the lift kit issues, with the Jeep now performing reliably and comfortably.

 

What were the challenges and solutions for installing an LED light bar on the Jeep?

Challenges and Solutions for Installing an LED Light Bar on a Jeep

Installing an LED light bar on a Jeep can be a rewarding project, but it comes with its own set of challenges. Here’s a breakdown of the main hurdles faced during installation and the creative solutions that helped overcome them.

Mounting Challenges

One of the initial difficulties was the size and fit of the light bar. Measuring 31.5 inches, the light bar was too deep to bolt directly onto the bumper without modifications.

Solution: Custom aluminum mounts were crafted to accommodate the light bar’s depth. These mounts were secured to the bumper using the existing factory bumper bolts, ensuring a robust and sturdy installation despite the unconventional setup.

Wiring and Switching Issues

Another challenge was integrating the light bar into the vehicle’s electrical system. A simple OEM-style switch was purchased, but integrating this switch posed a few issues.

Solution: The switch was connected through a relay, utilizing the same power terminal as the headlight relay conversion. This ensured that the light bar operated efficiently with the existing electrical setup. A replacement bezel from a parts Jeep had to be sourced to install the switch, as the original didn’t have the necessary fitting space.

Switch Visibility Concerns

Disappointment arose with the switch’s illumination – while it indicated when the light was on, the entire switch didn’t light up as desired.

Solution: While considering reverting to a factory fog light switch for better illumination, the current switch was retained due to its clear labeling.

Design and Aesthetics

Aesthetic appeal was another consideration. Altering the bumper’s end caps to fit around the new mounts wasn’t visually pleasing.

Solution: The decision to prioritize functionality over aesthetics was made. Although not perfect in appearance, the utility of the light bar justified the unconventional look.

Future Compatibility

A potential issue was the compatibility of the light bar with future bumper upgrades. Most aftermarket bumpers might not accommodate such a wide light bar.

Solution: For now, the light bar remains in place, providing excellent trail illumination. However, future modifications will be considered based on compatibility with preferred bumpers while maintaining the current setup until then.

In summary, the installation process required creative solutions to mounting, wiring, and aesthetic challenges. Nonetheless, the end result ensures that trails are lit brightly and effectively, showcasing ingenuity and resourcefulness in vehicle modification.

 

How did the owner address the issue of the license plate being blocked after installing the tire carrier?

After installing the tire carrier, the owner faced a challenge with the license plate being obscured. To tackle this, they first attempted to use bolts with integrated LEDs for illuminating the plate. Although this seemed like an innovative solution, the bolts proved to be of poor quality and broke easily.

Consequently, the owner had to drill four holes into the vehicle’s hatch. Recognizing the need for effective lighting, they switched to a more reliable option: an LED strip. This strip was connected to the existing license plate light wiring. To ensure durability and compliance, the wiring was carefully soldered and secured with heat-shrink tubing.

In the end, the license plate was properly illuminated, adhering to legal requirements and ensuring visibility.

 

What is the backstory of the 1999 Jeep XJ involved in the overland build?

The journey of the 1999 Jeep XJ began in early 2010, when it was acquired with 130,000 miles on the odometer. A thrifty purchase at $3,500, it was chosen for its value and potential for adventure. Since then, the Jeep has gone through extensive maintenance and gradual improvements, primarily at the hands of the owner, a DIY enthusiast. Only when specialized tools were required did a local mechanic lend a hand.

Throughout the years, virtually the entire cooling system received an overhaul, including the alternator, battery, radiator, heater core, water pump, and thermostat. The longevity of the tires was notable, achieving about 65,000 miles on a set before needing a replacement. Interior components like the stereo and speakers were updated to enhance the driving experience. The Jeep’s suspension was also maintained with new bushings and worn components replaced as needed.

As time passed and the Jeep clocked over 210,000 miles, the tires once again signaled for a change. This juncture offered a new possibility: transforming the trusty vehicle into an overland-ready companion instead of opting for a different one. The decision to modify rather than replace was fueled by the owner’s familiarity with the Jeep’s character and performance. Its efficient fuel consumption and complete set of necessary features, all packed into a compact design, made it an ideal candidate for this next chapter.

 

What steps did the owner take to replace the remote keyless entry for the Jeep?

To replace the remote keyless entry for the Jeep, the owner followed a straightforward process that turned out to be surprisingly simple and cost-effective. Here’s how they did it:

1. Identify the Need: The owner initially realized the Jeep was supposed to have a remote keyless entry by checking the build sheet, even though it didn’t come with one at the time of purchase.
2. Purchase a Replacement: They decided to buy a replacement remote online, ensuring it was compatible with their Jeep model.
3. Visit the Dealership: Armed with the new remote, the owner visited a dealership to have it programmed. Initially, the staff seemed doubtful about the compatibility.
4. Get Assistance from a Mechanic: Determined to make it work, the owner requested assistance from a mechanic. The mechanic demonstrated the process, which only took about five minutes to program the new remote successfully.

In the end, this straightforward approach, costing around $55, brought the Jeep’s remote keyless entry back into play, enhancing convenience for the owner.

 

Why did the owner decide to modify the Jeep for overland travel instead of buying a new vehicle?

The idea behind this build was to create a comfortable, capable, easy to fix, and inexpensive to keep on the road overland vehicle that could be completely self-sufficient and off the grid for up to seven days.

Instead of purchasing a new vehicle, I opted to modify the one I already had. This decision was driven by several factors:

• Familiarity and Fondness: I’m very familiar with my current vehicle and still have a certain fondness for it. It’s a reliable companion that I’ve grown accustomed to over the years.
• Efficiency and Features: It offers decent MPG and includes all the features I need in a compact package. This is particularly appealing to me as I generally dislike driving large vehicles.
• Practicality and Cost: Modifying it is more cost-effective than buying a new one. It allows me to tailor the vehicle to my specific needs without the financial burden of a new purchase.

By focusing on these key aspects, the vehicle becomes not just a means of transport but a trusted ally in the pursuit of adventure.

 

What benefits does the vehicle provide that support the owner’s lifestyle?

It provides a compact and efficient solution with the right features, aligning with the owner’s lifestyle needs.

 

How does the vehicle’s size factor into the decision?

The owner prefers smaller vehicles as they generally dislike driving larger ones.

 

What are the practical reasons for keeping the vehicle?

The vehicle offers good fuel efficiency and includes all necessary features, making it a practical choice.

 

Does the owner still like the vehicle?

Yes, the owner has an ongoing fondness for it, indicating a personal attachment.

 

Why is the owner sticking with the current vehicle?

The owner is very knowledgeable about the vehicle, which suggests a level of comfort and trust in its performance.

 

What modifications were necessary to install a rear bumper and tire carrier on the Jeep?

The rear bumper is a custom-made unit complete with a spare tire swing out and lockable double jerrican holder. To make room for these additions, I first removed the spare tire from the cargo area, which freed up space for future enhancements like a potential drawer system. This initial step was straightforward, but it set the stage for the more involved tasks ahead.

Next, I tackled the removal of the mud flaps, as they weren’t compatible with the new rocker guards. Although this wasn’t initially planned, it turned out to be a necessary modification. The rocker guards were robust and fit well, although they left a slight gap that wasn’t noticeable once everything was assembled.

Completing the installation was relatively smooth, thanks to clear instructions that guided me through each step. However, a new challenge arose: the bumper blocked the license plate. To address this, I drilled four holes in the hatch—an unexpected twist in the process. I initially tried using LED bolts to illuminate the plate, but they proved unreliable, breaking with minimal tightening. I switched to an LED strip, soldering and heat-shrinking it to the existing license plate light for a clean and legal finish.

The end result was a rugged and functional setup that not only enhanced the vehicle’s utility but also maintained compliance with road regulations.

 

What solutions were implemented to address these challenges?

To solve the license plate lighting issue, an LED strip was installed and wired into the existing license plate light, ensuring it looked proper and met legal requirements.

 

What specific challenges were encountered during installation?

Drilling holes in the hatch for the license plate was a challenge, and the initial LED bolts used for lighting were of poor quality and broke easily.

 

How difficult was the installation process?

The installation was straightforward, with clear instructions provided, making it manageable.

 

Were there any gaps or fitment issues during installation?

There was a slight gap, but it wasn’t noticeable once everything was assembled.

 

What components needed to be removed or altered to accommodate the new bumper?

The spare tire was removed from the cargo area, and the mud flaps were also taken off because the new rocker guards didn’t have holes for them.

 

What improvements were made to the Jeep’s ride quality after the lift kit installation?

The entire lift kit has since been upgraded to higher-quality parts, which offer up a much better ride. After the initial installation, it became clear that the ride was not as smooth as expected. The vehicle exhibited some handling issues, like a wonky steering feel and an occasional wobble when hitting bumps.

To tackle these problems, I identified that one of the rear shocks was defective; it would collapse but refused to rebound. After contacting the manufacturer, I received a refund for the faulty shock.

Beyond just replacing shocks, I took further measures to enhance the Jeep’s drive experience. I installed an adjustable track bar to stabilize the steering. A drop pitman arm was added to improve the steering geometry and extended sway bar end links were fitted to maintain proper suspension articulation.

The installation of the pitman arm was a bit challenging—it involved breaking two pullers before eventually taking it to a shop, where it was replaced swiftly with an impact wrench and puller.

Now, the Jeep rides smoothly, steers precisely, and handles bumps with ease, making every drive a pleasure.

 

What was the outcome of the improvements?

The outcome of the improvements was positive, resulting in a vehicle that rides smoothly, steers properly, and handles bumps effectively.

 

What challenges were faced during the installation or upgrade process?

A significant challenge was encountered when trying to replace the pitman arm, which resulted in breaking two pitman arm pullers. Ultimately, it required professional assistance and an impact wrench to complete the installation.

 

What specific components were involved in the improvement process?

The improvement process involved specific components such as a Rough Country adjustable track bar, a drop pitman arm from Rusty’s, and Rusty’s extended sway bar end links.

 

How were these issues identified and addressed?

The issues were identified through driving experience, revealing the shock problem upon removal. To address these, the faulty shock was returned for a refund, and new components like an adjustable track bar, a drop pitman arm, and extended sway bar end links were ordered and installed.

 

What issues were encountered after the initial installation?

After the initial installation, the ride was uncomfortable due to a faulty rear shock. Additionally, there were problems with steering, and occasionally, hitting a large bump would initiate a wobble.

 

What parts have been replaced on the Jeep XJ over the years?

The radiator was upgraded to a Mopar HD unit, to keep the XJ running cool in the 100-degree Virginia summer heat, where Schalow lives. The front axle is a stock D30 with a Lockright Locker, while the rear is a non C-clip D35 out of a 1986 XJ, with 4.10 gears and a Lockright Locker. Its brake lines were also extended at all four corners, to work with the 3-inch lift, and the headlights were upgraded to improve nighttime visibility.

Over the years, various essential components have been replaced to maintain optimal performance and reliability. Here’s a closer look at the parts that have seen upgrades or replacements:

• Alternator & Battery: These have been updated a couple of times to ensure the electrical system remains in peak condition.
• Cooling System: Besides the radiator, the heater core, water pump, and thermostat have all been replaced, essentially overhauling the entire cooling system for maximum efficiency.
• Gaskets and O-rings: Key elements like the valve cover and oil filter shaft gaskets have been swapped out, preventing leaks and maintaining engine integrity.
• Tires: Achieving about 65k miles on a set of 235/76/15 BFG ATs, the tires were replaced to maintain road grip and off-road capability.
• Interior and Audio Components: Various interior parts, including the stereo and speakers, have been refreshed to enhance the driving experience.
• Suspension Components: As they wore out, bushings and other suspension elements were replaced to preserve the smooth handling of the vehicle.
• Sensors: Various sensors have been updated to keep all systems running smoothly and efficiently.

These meticulous upgrades and replacements ensure that the Jeep XJ is not only performing at its best but is also prepared to tackle any adventure with confidence.

 

What suspension components have been replaced?

As they wore out, bushings and other suspension elements were replaced to maintain handling and stability.

 

What interior parts have been replaced?

The interior saw upgrades with new parts, including the stereo and speakers, for better sound quality.

 

What is the tire replacement history?

A set of BFG AT tires with dimensions 235/76/15 was replaced after approximately 65,000 miles.

 

What gaskets and seals have been replaced?

Various gaskets and o-rings, such as those for the valve cover and oil filter shaft, have been replaced to prevent leaks.

 

What cooling system components have been replaced?

Key parts of the cooling system, including the radiator, heater core, water pump, and thermostat, have been completely overhauled.

 

What maintenance parts have been replaced?

The alternator and battery have been replaced multiple times to ensure reliable performance.

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