Jeep Cherokee XJ Budget Build

Jeep Budget Build Lifted Jeep Front Three Quarter

If you drive an older 4x4 and you wheel on a budget, this story is for you. We set out to improve a well-worn, 204,000-mile, 1996 Jeep Cherokee to show how its trailability can be enhanced without parting with a lot of cash. This particular vehicle is owned by a college-age, budget-minded wheeler and was purchased for $1,500. Previous to this install, he had made a few modifications to the rig, including a home-fabbed rear bumper and roof rack. The XJ also sports an eBay-sourced front bumper, forward-facing aftermarket lighting, and a Warn XD9000i winch. Like some rigs with this mileage and age, the rig had a few problems. The list included a broken front sway bar link and an out-of-whack alignment that had wasted the front tires.

Jeep Budget Build Stock Jeep Front Three Quarter

Our goals were to keep our parts tally under $1,000 for this build, make the vehicle more capable off-highway, and repair some of its broken and worn components.

We chose to use a 3-inch lift from Zone Offroad Products. Zone also offers a 2-inch lift and a 4½-inch lift for the XJ. We were tempted to install the 4½-inch lift, but then we knew we’d want larger tires, which would increase costs. Larger tires would also have an effect on the axle gearing, potentially requiring more costly upgrades in the form of new axle gears. The 4½-inch kit also would’ve pushed us over our parts budget. By sticking with the 3-inch kit we had the budget to take advantage of the optional shock upgrade and it replaces the twin-tube hydraulic shocks with twin-tube gas Nitro shocks. Well within our budget were a few other upgrades as well. We ordered the transfer-case drop kit to help eliminate driveline vibration caused by the lift; we installed sway bar disconnects to improve frontend flex; and we added a steering stabilizer kit to replace the used up OE unit. You can see the pricing for all of the items we installed in the sidebar.

The install was handled by the team at Attitude Performance in Arlington Heights, Illinois. Not only are they well-versed in XJ upgrades, they also know what to expect, and do, with the challenges posed by the vast amount of corrosion found under older rigs like this one.

Follow along as we show you the highlights of this low-buck install.

The Bottom Line
We replaced the well-worn P235/75R15 (28.9x9.30-15) Goodyear Wrangler RT/S tires and factory wheels with a set of used 30x9.50R15 Goodyear Wrangler GS/A tires on factory TJ wheels. We chose this wheel/tire combination because it’s typical of what you’ll find for sale on Craigslist or in your local newspaper at far lower cost than new tires and wheels. All five tires are in great shape with very little wear, and the wheels are in excellent condition. The tires are slightly larger in diameter than the ones they replaced and they offer significantly improved traction.

When we RTI’d the XJ stock (with its broken front sway bar link) it traveled 49.5 inches up our 20-degree ramp to earn a score of 490. After the install (with both sway bar links actually connected), it traveled 38.5 inches up the ramp to earn a score of 381. The big flex came when we disconnected the sway bar and the XJ climbed 63 inches up the ramp to earn a score of 624.

Before the install, we measured an approach angle of 32.7 degrees and a departure angle of 31.3 degrees. After the install, those numbers improved to 38 degrees at each end. This is an improvement of 16 percent and 21 percent respectively. The front bumper-to-ground height climbed from 16½ inches to 21 inches and the rear bumper-to-ground height improved to 21¾ inches from 16½ inches. This is a 27 percent and 32 percent increase respectively.

The owner of this XJ reports that the ride is “pretty smooth for a lifted Jeep.” And he notes that the SUV was used extensively during the winter of 2010-11 and it got through the snow with ease. As a bonus, the rig definitely looks better with the added lift and the new wheel/tire combination. Overall, we’re pretty happy with the return on our budget-minded investment

Kit Specs
This Zone Offroad 3-inch kit for the XJ allows fitment of up to a 31x10.50 tire on a 15x8 wheel with 3½ to 4 inches of backspacing.

The Cost
All total, parts for this XJ had a street price of $834.65 at time of print. The list included the Zone Offroad 3-inch suspension lift ($290.66), gas shock upgrade ($21.08), 1-inch transfer case drop ($33.46), sway bar disconnects ($99.95), and steering stabilizer kit ($39.50). The used Wrangler TJ wheels and tires cost $350. An alignment is mandatory after this install and cost the owner approximately $100 at a local new car dealership. Not comfortable with an install like this? Matt Dinelli at Attitude Performance says that his labor cost typically starts at approximately $420 and increases depending on how much corrosion or other surprises he encounters.

This pile o’ parts contains all of the Zone Offroad items we installed. The collection included the basic lift kit, upgraded gas shocks, steering stabilizer kit, transfer-case drop kit, and sway bar disconnects.
This pile o’ parts contains all of the Zone Offroad items we installed. The collection inc
Like many older, high-mileage rigs, this XJ had some broken parts. The most glaring was a broken driver-side sway bar link. The new sway bar disconnects would remedy this problem and help improve drivability when connected.
Like many older, high-mileage rigs, this XJ had some broken parts. The most glaring was a
If you live in the Rust Belt and your rig is older, like this XJ, you’ll need to plan to battle corrosion. In this case, Attitude Performance owner Matt Dinelli had to force out the lower OE link bolts that were rusted in place from 15 road salt-saturated winters. These OE parts had to go so the new disconnect studs could be installed. The passenger-side bolt was eventually removed with an air hammer, but this stubborn driver-side bolt had to be heated with a torch before it would break free.
If you live in the Rust Belt and your rig is older, like this XJ, you’ll need to plan to b

Dinelli noticed that sometime during the XJ’s life, someone had snapped the head off one of the passenger-side sway bar mounting bolts, so he drilled out the bolt shank and then tapped the hole before he installed a new bolt.
Dinelli noticed that sometime during the XJ’s life, someone had snapped the head off one o
The new Zone coil springs are made in the U.S. and provide three inches of lift. Zone says they're designed for off-highway use so there is no need for bumpstop extensions. They claim that the springs can be smashed to the bottom and always come back thanks to the correct size wire with correct spring rate.
The new Zone coil springs are made in the U.S. and provide three inches of lift. Zone says
This driver-side sway bar disconnect stud. Like the new passenger-side stud, this is what the new links will attach to for highway driving. The Zone sway bar disconnects we installed fits XJs with 3 to 41/2 inches of lift and are made from 5/8-inch solid steel and urethane mounts.
This driver-side sway bar disconnect stud. Like the new passenger-side stud, this is what

Because the kit reuses the factory track bar disconnect, as opposed to an adjustable track bar, the track bar mounting position at the axle has to be modified to help compensate for the lift. A new hole is drilled about 3/4 of an inch inboard of the factory hole.
Because the kit reuses the factory track bar disconnect, as opposed to an adjustable track
Here you can see the modified track bar mounting position.
Each end of the sway bar gets a new U-bracket. This is the upper mounting position for the new sway bar links.
Each end of the sway bar gets a new U-bracket. This is the upper mounting position for the

The Zone steering stabilizer mounts in the factory position, but the kit includes a new stud mount for the tie rod. Here you can see the stud installed.
The Zone steering stabilizer mounts in the factory position, but the kit includes a new st
Here you can see the steering stabilizer being attached to the new stud assembly.
And here is how the frontend looks in completed form. Note the optional black gas shocks. The owner chose to add red shock boots.
And here is how the frontend looks in completed form. Note the optional black gas shocks.

Moving to the rear of the vehicle, Dinelli notes that a problem area on rustbelt XJs is the upper mounting bolts for the shocks. Oftentimes, the bolts are rusted to the nuts, which are welded to the unibody. The bolt heads often break off during removal, forcing the installer to either drill and re-tap the holes or break the nuts off and use a bolt/nut arrangement to mount the shock at the top.
Moving to the rear of the vehicle, Dinelli notes that a problem area on rustbelt XJs is th
To lift the rear of the XJ, the kit includes a pair of new add-a-leaf springs, which are added to the leaf packs. Zone says the springs have been designed and tested to hold up over the long haul without creating a harsh ride.
To lift the rear of the XJ, the kit includes a pair of new add-a-leaf springs, which are a
New U-bolts are included with the kit. When ordering the kit you need to specify whether your XJ has the Chrysler 81/4-inch axle or the Dana 35 axle so you get the correct U-bolts for your application.
New U-bolts are included with the kit. When ordering the kit you need to specify whether y

Here's how the completed rearend looks. Like the front, the rear gas shocks are custom-valved for the XJ application.
Here's how the completed rearend looks. Like the front, the rear gas shocks are custom-val
The Taller lift means there's a chance of rear driveline vibration due to increased driveshaft angles. The Zone 1-inch transfer case drop helps to alleviate that problem. The spacers simply fit on each side between the framerails and crossmember. They're held in place using included hardware.
The Taller lift means there's a chance of rear driveline vibration due to increased drives
In stock form, the XJ traveled 49.5 inches up our 20-degree RTI ramp with a broken driver-side sway bar link.
In stock form, the XJ traveled 49.5 inches up our 20-degree RTI ramp with a broken driver-