Jeep Cherokee XJ Rough Country Long Arm Kit

Jeep Cherokee Xj Rough Country Long Arm Suspension Flexing

One of the hottest SUV platforms for buildups is the Jeep Cherokee XJ. Produced from 1984 to 2001, these solid front-axle rigs are simple, plentiful, and inexpensive. They're just screaming to be modified and wheeled.

Naturally, one of the hottest mods is a suspension lift. Long-arm kits are very popular, and there are a number of these kits on the market. Rough Country Suspension Systems has just jumped in the long-arm fray by unveiling a trio of brand-new, very competitively priced kits for the XJ. They now offer a 41/2-inch kit with rear add-a-leaf and shackles (MSRP $1,099.95), a 41/2-inch kit with full rear spring packs (MSRP $1,199.95), and a 61/2-inch kit with full rear spring packs (MSRP $1,249.95).

We recently traveled to Rough Country's headquarters in Dyersburg, Tennessee, to install the 41/2-inch kit with full rear spring pack. This kit was developed using 32x11.50-15 tires on 15x8-inch aftermarket wheels with 33/4-inch backspacing. If you have extra bolt-on equipment like a winch and/or aftermarket front bumper, Rough Country offers optional polyurethane coil-spring isolator pads that help compensate for the added weight, and they boost ride height by 3/4 inch.

When we asked Rough Country what their goals were with this kit, they responded by saying, "Our goal was to bring an XJ long-arm kit to the market that incorporated a great design, strong components, and a market-leading price."

Here's a look at the major components of the kit and how they install.

This photo shows the vast majority of the components we installed. Note that the kit includes a transmission skidplate, premium Performance 2.2-series shock absorbers, sway bar disconnects, new stainless steel brake lines, and an adjustable track bar.
This photo shows the vast majority of the components we installed. Note that the kit inclu
Installing the new system begins up front. The stock shock absorbers, sway bar links, track bar, coil springs, and control arms all need to be removed.
Installing the new system begins up front. The stock shock absorbers, sway bar links, trac
The stock lower control arm mounts are removed to make room for the new control arms. Typically, this is done with a reciprocating saw. The illustrated instructions included with the kit show exactly where to make the cuts.
The stock lower control arm mounts are removed to make room for the new control arms. Typi

After removing the lower control-arm mounts, any ragged edges are ground smooth and the area is painted to resist corrosion. Overall, the cutting and grinding takes about an hour to complete.
After removing the lower control-arm mounts, any ragged edges are ground smooth and the ar
With the transmission/transfer case supported, the stock transmission crossmember is removed.
With the transmission/transfer case supported, the stock transmission crossmember is remov
The new transmission crossmember, which also incorporates mounts for the new lower control arms, mounts in place of the factory transmission crossmember. This new crossmember is made from 1/4-inch-thick steel.
The new transmission crossmember, which also incorporates mounts for the new lower control

New side plates are installed on each side of the new transmission crossmember to bolster strength. Installation of these plates requires drilling two holes per side into the unibody. With the side plates held in position temporarily via two lower crossmember bolts, the areas to be drilled are marked and then drilled out. The front holes on each side are drilled out to 17/32 inch, while the rear holes are drilled out to 25/32 inch after removing the side plates.
New side plates are installed on each side of the new transmission crossmember to bolster
Crush sleeves are used in the rear side plate holes on each side, while the front holes receive bolts and flag nuts. A total of five bolts per side hold the new crossmember and side plates in place.
Crush sleeves are used in the rear side plate holes on each side, while the front holes re
New stainless steel brake lines are included with the kit for both the front and rear axle. They're not only longer to compensate for the taller lift, they're also better quality than stock.
New stainless steel brake lines are included with the kit for both the front and rear axle

The new lower control arms are approximately 133/4 inches longer than the stock arms, and they're made from 2-inch-diameter, 0.250-inch-wall DOM material. After adjusting their length via the instructions, they're bolted to the new crossmember and the axle.
The new lower control arms are approximately 133/4 inches longer than the stock arms, and
Like the lower control arms, the new upper control arms are adjusted to length via the instructions and then bolted in position. The upper control arms are made from 13/4-inch-diameter, 0.120-inch-wall DOM material.
Like the lower control arms, the new upper control arms are adjusted to length via the ins
Each upper and lower control arm is equipped with a Rough Country flex joint. In the lower portion of the photo, you can see some of the components of these joints. Each has an eye ring made from 5/16-inch steel, hardened washers, injection-molded bushings, steel zinc-coated internal pivot ball, and hardened snap rings. At the top of the image is an assembled flex joint, and as you can see, they are greasable. They are also rebuildable.
Each upper and lower control arm is equipped with a Rough Country flex joint. In the lower