When American Motors Corporation (AMC) debuted the compact, solid axle-equipped Jeep Cherokee XJ in 1983 as an '84 model, it hit the consumer 4x4 SUV world right between the eyes. For other SUV manufacturers, it was like Jeep had walked into their house and given them a wedgie.
For better or worse, the XJ boasted the first uniframe architecture in a 4x4 domestic truck in a world dominated by body-on-frame design. It was also the first compact sport-utility to offer two- and four-door models. It was radically smaller in size than previous Jeep SUVs. It was lauded for its lack of exterior bloat and wise use of interior space, among other things. The reality was that these attributes combined to help produce a vehicle that offered better fuel mileage and improved maneuverability than its predecessor, both on- and off-highway. The new XJ was an instant hit.
During its 17-year production run, the XJ received very few major modifications. The first and last semi-big change came in 1997 when the XJ got a new interior, exterior enhancements, and dual airbags. The XJ Cherokee has been out of production for five years, but that insignificant little fact hasn't quelled its popularity or demand.
As groundbreaking and popular as these SUVs were, they were by no means perfect. As a matter of fact, some had quirks that were downright aggravating. In this installment of "Weak Links, Strong Fixes," we examine items that could be an issue. And as we do with all of the installments in this ongoing series, we've consulted with the experts and combined their knowledge and experience with ours to offer suggestions on how to fix 'em.
Fractured Mounts
Weak link: Lower front control-arm mounts
Models affected: All
What happens: From the factory, the lower control-arm mounts are only welded to the Dana 30 front axlehousing on the outsides of the mounts. Further, the welds don't always continue to the edge of the mount, which allows cracks to start. The stresses of extreme 'wheeling can cause the mounts to separate from the axlehousing.
Strong fix: North America XJ Association (NAXJA) member Richard Gauthier notes that a quick do-it-yourself fix is to weld the insides of the brackets and ensure that the weld continues all the way to the edges. Burnsville Off Road in Burnsville, Minnesota, recommends welding a 3/16-inch plate across the front of the mounts to add even more strength.
Contact: Burnsville Off Road, 952/890-3990, www.burnsvilleoffroad.com
Limbo Bar
Weak link: Tie rod location
Models affected: All
What happens: The tie rod on the Dana 30 front axle is mounted to the bottom of the steering knuckles. Naturally, this makes the tie rod susceptible to trail damage because of its low position.
Strong fix: An inexpensive fix is to mount the tie rod on top of the knuckles using the Tie Rod Flip Insert Kit from Goferit Offroad. To install, you simply drill out the tapered portion of the knuckle 0.75 inch, tap in the new insert and weld the lip. The new bushing has the correct taper to accept stock tie-rod ends, and the kit includes a new special spiral-lock flanged nut for the tie-rod bolts.
Contact: Goferit Offroad, 336/317-7130, www.goferitoffroad.com
Cracking Up
Weak link: 4.0L head
Models affected: Mid '99-'01
What happens: NAXJA member Travis McVey points out that weaker head castings on these 4.0L engines can cause them to crack. He notes that the cracking usually occurs between the third and fourth exhaust ports.
Strong fix: McVey notes that the hot ticket is to install a head from a '96-'98 4.0L engine. Not only are these heads stronger, but the ports are better matched and will flow better, resulting in more power.
Contact: Yourlocal salvage yard
Failing 4WD
Weak link: Dana 30 vacuum actuator
Models affected: Some '84-'91
What happens: Yanking the transfer-case lever into four-wheel drive activates a front axle-mounted vacuum actuator. This unit is designed to move a collar laterally and engage the front axleshaft. More often than not, this evil component often fails for one reason or another. When this happens, the transfer case engages but the front axle doesn't. The result is no four-wheel drive.
Strong fix: There are actually two fixes for this, and the same company makes them both. One is the 4x4 Posi-Lok, which replaces the vacuum system with a cable-actuated actuator (say that 10 times fast). The other is the Perm-Lok (shown), which also replaces the vacuum actuator, but is not selectable because it permanently engages the front axle.
Contact: 4x4 Posi-Lok, 517/279-7177, www.4x4posi-lok.com
Alternating Current
Weak link: Instrument cluster
Models affected: '97 and later
What happens: The stock connector for the instrument cluster is susceptible to minor oxidation, which could cause sporadic or no operation of the airbag warning light, tachometer, or speedometer.
Strong fix: You could simply clean the connector terminals, but this is a temporary fix. Your best bet is to contact your local Jeep dealer and order the parts to fix it right. Our friends at Bryden Motors in Beloit, Wisconsin (the folks who service our long-term Liberty CRD), tell us that per Technical Service Bulletin 08-15-99 it can be repaired using part numbers 05016261 (cluster connector patch harness), 04856975 (electric contact cleaner), and 04778570 (heat-shrink tubing). Installation of the revised instrument cluster connector will require removal of the gauge cluster along with contact cleaning and soldering.
Contact: Bryden Motors (Jeep dealer), 800/727-9336, www.brydenmotors.com, or your local Jeep dealer
Scrawny Stoppers
Weak link: Rear drum brakes
Models affected: All
What happens: XJs came equipped from the factory with front disc and rear drum brakes. Their performance was adequate if the vehicle remained stock, but larger tires and the addition of weighty bolt-ons caused their abilities to deteriorate in a big way.
Strong fix: Swap to rear disc brakes. One option is to install one of the kits offered by TeraFlex. They're available for XJs equipped with the Dana 35, Dana 44, or Corporate 8 1/2-inch axles. The bolt-on kits provide everything you'll need including brake lines, rotors, backing plates, calipers, pads, and hardware. They also utilize a drum-style parking brake that is said to provide outstanding holding power when compared to other disc-brake conversions. Another option is comparatively low-buck. Burnsville Off Road notes that for its customers whose rigs roll on Dana 35 or 44 rear axles, the company routinely replaces the drum brakes with rear disc brakes from a '95-'98 Grand Cherokee. These discs can also be found on some '94 Grand Cherokees as well.
Contact: Burnsville Off Road; TeraFlex, 801/288-2585, www.teraflex.biz
Small Joints
Weak link: Front axleshaft U-joints
Models affected: '84-'96
What happens: These axles use weak Spicer 260-X U-joints, which often fail-especially on vehicles fitted with larger tires. That they fail is bad enough, but even worse, they often trash the axleshaft yoke when they break.
Strong fix: Upgrade the axleshafts. Among the manufacturers offering upgrade kits for these axles is Superior Axle & Gear. Superior's axleshafts have the same spline count and overall diameter as the stock units but use a larger 297-X U-joint.
Contact: Superior Axle & Gear, 888/522-2953, www.superioraxle.com