Tag Archives: xj

Jeep Cherokee XJ Build

In November of 2022, I acquired a 2001 Jeep Cherokee XJ with just about 185,000 miles and in need of some TLC. I’ve always found myself fascinated by the Jeep Cherokees, and have always wanted to purchase one. I like how simple they are, how relatively easy they are to work on, and how reliable they are known for being. That said, after over 20 years on the road and 185,000 mi, this car is definitely showing its age and is in need of quite a bit of work to become a daily driver. I have no intention of making this an off-road first vehicle, and instead would like to focus on daily comforts and features. Ultimately, I’d like for this car to be my daily driver for shorter trips, for winter, and for camping.

The Problems

This XJ has a number of issues, which I’ll quickly outline here:

  • Engine knock on cold start
  • Exhaust leak
  • Rust
    • Doors are too far gone for me to want to fix
    • Tailgate is too far gone for me to want to fix
    • Rear quarter panels behind bumper end caps are rotted out
    • Rear uniframe is in need of repair near fuel neck filler hole
    • Rocker panels are bubbling
  • A/C does not work
  • Heater core is leaking, jammed blend door (dried coolant)
  • Minor coolant leak near radiator
  • Driver-side window regulator is dying
  • Driver-side window lockout is broken, preventing passengers from rolling their windows down and up
  • Missing gas tank exhaust hanger
  • Fuel gauge doesn’t work properly below ¼ tank
  • Tailgate mechanism is stubborn due to rust
  • Needs brakes
  • Needs e-brake to be adjusted
  • 4WD is noisy – fluid is likely ancient and in need of change
  • Spark plugs and wires need done
  • U-joints likely need replacement
  • Unhappy with existing light bar installation
  • Dim headlights
  • Broken fog lights
  • Missing fuel tank shield & exhaust hanger

The Goal

I have intentions of slowly chipping away at the problem list one junk yard/Rock auto purchase at a time. First on the docket is the heater core, window regulator, and brakes. With these, the car will be fully operable again, for a short time anyway. Ultimately, I’d like to protect the XJ in areas it is prone to damage while also improving the safety of it.

Immediately:

  • New spark plugs and coil pack – done
  • Window regulator for driver – done
  • Driver’s window switch assembly – done
  • Replace fog lights – done
  • Upgrade to aftermarket headlight wiring harness – done (will post details separately)
  • Brakes – WIP
  • Heater core/AC evaporator/Blend door & clean HVAC assembly
  • Install AJ’s Offroad Armor Tanker Tire Carrier rear bumper
  • Install Rusty’s Rear Corner Cut Panels – WIP

200,000 miles:

Whenever:

  • Headliner
  • Carpet
  • Check out the floor pans and cry
  • Air conditioning
  • Replace fuel pump
  • Frame stiffeners for rear of vehicle

The Upgrades

Audio

Stereo

Joying 8.8″ Stereo: https://www.amazon.com/JOYING-Android-Universal-Bluetooth-Subwoofer/dp/B08K36DPLH

Subwoofer Enclosure
XJ-POD

Body

Interior

  • Heated mirrors
  • Heated seats

Electrical

Headlight Harness

K Suspension offers an affordable harness which routes your XJ’s headlight power directly to your headlights, preventing the interior switch from having to handle the amperage of your headlights. There is a higher quality version of this from Jeep Cables, but I found the K Suspension harness was perfectly adequate. https://www.ksuspensionfab.com/store/p6/H4_Upgraded_Headlight_Harness.html

XJ “Big 7” cable upgrade

The cables in my XJ are tired and asking to be replaced. I have already had to make emergency repairs once, so I will be replacing them with the “Big 7 Kit” from Jeep Cables. https://www.jeepcables.com/products/xj-big-7-complete-kit-cherokee-87-01

Headlights

I am going against better wisdom and am looking at this headlight set because they look cool. They probably aren’t the best. https://www.amazon.com/dp/B0BWBXB4TT/

Drivetrain