CHEAP JEEP XJ CHEROKEE BUILD TIPS
Four Wheeler|November 2022
I have a '00 Jeep XJ Cherokee Sport that's pretty much bone stock. I want to build it up on the cheap to fit 32-inch tires and hit some trails in southwestern Colorado. I know these Jeeps have been built 1,000 different ways but wondered if you have any tips or tricks that will help me keep the budget down while improving the off-road abilities of the Jeep without ruining its on-road manners too much. I also found and scooped up an XJ Dana 44 rear axle for this build from a junkyard and will have it re-geared to work with the slightly larger tires.
CHEAP JEEP XJ CHEROKEE BUILD TIPS

Welcome to the addictive world of one of the most used and modified Jeeps. XJs were built for a long time and many folks have changed them to suit their needs, from mild to wild. I've owned at least three XJs, and you have a good one in one of the last model years built. It will have the venerable AMC 4.0L 1-6, a torquey and reliable engine that lots of enthusiast's love. Behind it is most likely an AW4 four-speed automatic (although a few XJs had the 4.0L and an NV3550 five-speed manual). From there you either have the NP242 or more likely an NP231, both of which are great transfer cases for a mild build. Your front axle will be a low-pinion Dana 30, the same axle that came from the factory in the TJ Wrangler. Your rear axle is either a 29-spline Chrysler 8.25 or a Dana 35. The Dana 44 you found is a mild upgrade over the Chrysler axle (which is pretty strong but is unfortunately a C-clip-style axle) and a definite upgrade over a Dana 35 ... it makes a better boat anchor than an axle.

This story is from the November 2022 edition of Four Wheeler.

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