Full-Traction Suspension - 6-Inch Lift - XJ Cherokee Trailrunner: Part 4

The XJ Cherokee is a prime candidate for suspension modifications. Con-quering the Jeep Speed Challenge and traversing the world's most rugged trails has earned the XJ prominence among four-wheelers. A suspension lift and oversized tires help the XJ Cherokee achieve these levels of performance. While 6 inches of lift puts a Jeep CJ or Wrangler into the 35- to 37-inch-diameter tire realm, the XJ Cherokee needs such height just to mount 33-inch tires.

For our "XJ Cherokee Trail Runner" project, Toyo's A/T Open Country LT285/75R16 tires provide an optimal choice for on- and off-pavement driving. Mounted on American Racing's impressive Mojave-series "ATX" Teflon-coated 16x8-inch rims, this wheel/tire combination requires a rugged, well-conceived 6-inch suspension package.

Full-Traction Suspension's FTS720601 Performance Suspension System has the ingredients our trail runner requires. The XJ Cherokee's unitized-body construction demands a "system" approach to chassis changes. For off-pavement pounding or Jeep Speed competition, any lift package short of a complete replacement suspension system would leave the XJ Cherokee chassis vulnerable to fatigue and damage.

Full-Traction Suspension (FTS) has taken each of the XJ's suspension and structural points into account. The system's rear leaf springs, massive in size and stamina, demand the hefty shackle upgrade provided in the package. The rugged FTS front suspension design delivers exceptional flex and articulation, pivoting from solid, mid-chassis mounting points. Control arms fabricated of 2x0.250-inch-wall DOM feature JM-16T Heim joints at the lower axle attachments. To back this up, FTS includes substantial frame brackets and upgrade hardware throughout the system.

Long, stout front coil springs; a dropped pitman arm; front stabilizer-bar disconnects; a stronger front track bar system; DOT-rated brake hoses; bump stops; rear-spring U-bolts; a host of plated, high-grade hardware; and the optional Full-Traction Suspension "M-Force" gas-pressurized shock absorbers rounded out our package. Advance Adapters' Slip-Yoke Eliminator kit (see our Jan. '05 issue) was necessary for this installation. Likewise, the precision, upgraded CV-type rear driveshaft by Powertrain Industries (a supplier to Full-Traction Suspension and the heavy-duty automotive and truck aftermarkets) is also essential for a 6-inch suspension height increase.

Our first on-highway driving experience proved the importance of a "suspension system" approach. Despite the heft of the front and rear springs, the ride quality has actually improved over stock. Cornering is firmer and readily predictable. The overall highway effect is stable-handling, with excellent road feel. Toyo's A/T Open Country tires provide sure, rock-steady grip, both on- and off-pavement. With air pressure adjusted for the light weight of the XJ Cherokee, these tires provide the right tread and traction for every season-and all types of terrain.

Off-pavement, from corrugated washboard to low-range crawling, this tire-and-wheel combination is tops. Toyo's tires have true multi-purpose capability. Considering their record on fullsize work trucks, these tires should last for years and years on an XJ Cherokee.

The switch from 3.55:1 to 4.10:1 axle ratios (see the Nov. and Dec. '05 issues) brings the XJ back to stock highway performance with the new 33-inch-diameter Toyo tires. Peppy and versatile with its AW-4 automatic transmission and 4.0L engine, this XJ now delivers the off-pavement performance a trail runner requires. Full-Traction Suspension's 6-inch long-arm system has transformed this light SUV grocery-grabber into a rugged trail-and-traction machine.

Overall, we now have a rock-crawling, multipurpose rig that qualifies as a trail runner. We can also get to and from the trails in comfort-and with great fuel economy, too. The next items on the list are upgraded bumpers and a trail recovery winch.

The stock XJ front end is similar to the TJ Wrangler's front end. This link-and-coil suspension has proven its worth both on- and off-pavement. The primary shortfalls with this system are limited ground clearance and no room for oversized tires. The XJ's latent trail-running ability hides beneath a suburban SUV profile.
The stock XJ front end is similar to the TJ Wrangler's front end. This link-and-coil suspe
Full-Traction Suspension's Performance Suspension System installation begins with the removal of stock components. Here, we've removed the steering pitman arm, the complete steering linkage, track bar, and sway bar. The stock steering linkage and steering damper shock are now out of the way. They will go back in place after installing the FTS720601 components. To prevent parts damage, always use the correct pullers when loosening the tie-rod ball studs and the pitman arm.
Full-Traction Suspension's Performance Suspension System installation begins with the remo
The stock front and rear springs will not be reused. Note that a chassis hoist and tripod stands enable safer lowering of the front axle assembly to remove the coil springs. We still use a spring compressor set to relieve tension on the coils during removal. At this stage, the stock upper and lower link arms are still in place.
The stock front and rear springs will not be reused. Note that a chassis hoist and tripod

Longer, DOT-approved brake hoses come with the suspension system. Here, we detach the front brake hoses, using care to keep debris from the system. Use clean plastic caps and plugs to seal the hydraulic system from contamination. New hoses and brackets will compensate for the 6-inch increase in chassis height.
Longer, DOT-approved brake hoses come with the suspension system. Here, we detach the fron
While the Full-Traction Suspension system is virtually bolt-on, one welding chore is necessary. Supplied with the package are two new and hefty front stabilizer axle brackets. To install these brackets, cut the original brackets as illustrated. Note the use of a plasma cutter to save time, minimize the heated area, and control the finished cut.
While the Full-Traction Suspension system is virtually bolt-on, one welding chore is neces
After a light touch-up and some prep with a surface grinder, the new bracket can be welded into place. Use a C-clamp to hold the new bracket while welding. This fit-up is not complicated. You will, however, need to do some minor cutting and welding.
After a light touch-up and some prep with a surface grinder, the new bracket can be welded

The finished installation of the bracket reflects Full-Traction Suspension's quality engineering. Welded in place and painted, the bracket took less than half an hour to install. The glossy black paint looks great and resists rust.
The finished installation of the bracket reflects Full-Traction Suspension's quality engin
This is the driver-side bracket installation; we're using a wire-feed MIG and 0.035-inch wire to perform this all-position welding. We catch the top of the bracket in the down position and run long stitch beads at the front. Stitch the bracket to the axlehousing the same way the factory welds were done on the original bracket. These new brackets are on to stay!
This is the driver-side bracket installation; we're using a wire-feed MIG and 0.035-inch w
After a coat of rust-resistant black paint is applied, this bracket is now ready to support the stabilizer bar. These brackets are the only parts that require welding or cutting. Considering the scope and caliber of this package, this is a tribute to the engineering prowess of Full-Traction Suspension.
After a coat of rust-resistant black paint is applied, this bracket is now ready to suppor

The track-bar bracket's bolt size increases with the hefty FTS replacement track bar. This is a quick and easy task. Get all of these modifications out of the way with the steering linkage removed-access is much simpler. It takes only a few minutes to remove the steering linkage with the correct pullers.
The track-bar bracket's bolt size increases with the hefty FTS replacement track bar. This
This double-bracket system provides the bracing and critical support necessary for the leading front link arms. While drilling is required, these brackets pick up factory bolt holes as well. The stock crossmember will bolt beneath the two members and add additional support. This system is built for the rigors of Jeep Speed Challenge competition.
This double-bracket system provides the bracing and critical support necessary for the lea
We have reinforced the stock crossmember by welding a 1/8-inch plate to the bottomside. This is not a requirement; however, with the crossmember lending strength to the link-arm supporting brackets, we want the added stamina. The crossmember, like the chassis itself, is heavy-gauge sheetmetal and can use the protection from trail obstacles and debris.
We have reinforced the stock crossmember by welding a 1/8-inch plate to the bottomside. Th

This side view of the brackets and link arms shows the area we sprayed with sealer/primer. Any time you drill holes in the frame or a unibody, the bare metal needs a coat of primer and undercoating where practical. Bare metal will enable rust to form and grow. In corrosive climates, this will lead to frame failure over time.
This side view of the brackets and link arms shows the area we sprayed with sealer/primer.
Full-Traction supplies many self-tapping bolts for sheetmetal areas and for the raised front bump stops. To ease coil-spring installation, we drill and tap the bump-stop locations. This enables placement of the bump stop within the spring during installation and allows us to easily thread the bolts into place once the spring is in position.
Full-Traction supplies many self-tapping bolts for sheetmetal areas and for the raised fro
Full-Traction Suspension now offers its own line of gas-pressurized shock absorbers. These optional "M-Force" shocks have the right tuning for on- and off-pavement use. Engineered to match the spring rates and driving styles of individual owners, these shock absorbers provide stable control and quality damping.
Full-Traction Suspension now offers its own line of gas-pressurized shock absorbers. These

With springs and shocks installed and the steering linkage and new track bar with bracket in place, the front system is nearly complete. Note the fitment and heft of components. The FTS720601 components meet or exceed all factory requirements while adding far more articulation than stock. Note the use of massive JM-16T Heim joints at the lower link arms. Full-Traction Suspension brings these major improvements to factory attachment points.
With springs and shocks installed and the steering linkage and new track bar with bracket
Adjustable link arms mean that alignment will require a trip to your local four-wheel alignment shop. Rough figures are possible by checking vehicle measurements from front-to-rear in cross. Pick common points at the front outer axle ends and rear spring center bolts of the axle. Here, we use an inclinometer to read the front-axle caster angle. Toe-in can be gauged with a tape measurement fore and aft of the front tires. Measure the tread close to the midline of the tires using common tread points.
Adjustable link arms mean that alignment will require a trip to your local four-wheel alig
Work at the rear axle begins with disconnecting the brake hose. Full-Traction Suspension supplies long brake lines of DOT-approved type. This package addresses all suspension lift concerns.
Work at the rear axle begins with disconnecting the brake hose. Full-Traction Suspension s

The rear springs are massive. Military wraps provide added security. Despite the heavy leaf and wrap design, these rugged springs provide excellent axle articulation and a compliant ride. The spring rate, combined with the use of M-Force gas-pressurized shock absorbers, delivers precise on- and off-pavement handling and ride quality.
The rear springs are massive. Military wraps provide added security. Despite the heavy lea
How are these for spring hangers? The factory components pale by comparison. This suspension system is well-tested at Jeep Speed competitions. Off-pavement crawling or highway cruising, the FTS720601 package delivers performance and stamina.
How are these for spring hangers? The factory components pale by comparison. This suspensi
Urethane bushings, hefty steel sleeves, and high-grade bolts hold the springs in place. Weight of the rear springs is not an issue, especially for gas-pressurized shock absorbers. A firm, predictable ride and good steering feel result from springs designed properly for a high-arch, 6-inch lift.
Urethane bushings, hefty steel sleeves, and high-grade bolts hold the springs in place. We

Once the rear suspension has been installed with M-Force shocks, the pinion shaft points upward as designed. This package uses a CV-type rear driveline, seen here. Powertrain Industries built this heavy-duty, all-Spicer-component driveline for the rigors of racing and hardcore four-wheeling.
Once the rear suspension has been installed with M-Force shocks, the pinion shaft points u
The CV-type joint uses genuine Spicer 1310-size U-joints. The Powertrain Industries driveline works in conjunction with Advance Adapters' slip-yoke eliminator kit. The transfer-case output and yoke is an Advance Adapters product that mates with this type of driveline. This new, fully-balanced driveshaft assembly is dramatically stronger than the OEM type.
The CV-type joint uses genuine Spicer 1310-size U-joints. The Powertrain Industries drivel
Powertrain Industries' driveline tubing size, coupler splines, and CV assembly exceed OE standards by a wide margin. At the rear 1310 joint, we install a new set of Spicer strap clamps and bolts with thread locker. This is a recommended procedure when removing and installing a driveline. The Spicer kit is inexpensive insurance for strap-type U-joint yokes.
Powertrain Industries' driveline tubing size, coupler splines, and CV assembly exceed OE s

This rear-to-front view of the front suspension package reveals the layout of link arms and fit-up of components. Always check the brake hose and tire clearance at the link arms. Check the link arm to OE frame bracket clearance as well. For this tire size and 4.5-inch wheel backspacing, we will need to adjust the steering stops to eliminate tire rub at the link arms. Brake hoses must clear the tires and all moving parts over the full range of suspension movement and steering travel.
This rear-to-front view of the front suspension package reveals the layout of link arms an
A final view of the chassis reveals quality engineering and a rugged suspension system. More than just a means for installing oversized tires, this long-arm, 6-inch suspension system transforms the XJ Cherokee into a robust, trail-running 4x4.
A final view of the chassis reveals quality engineering and a rugged suspension system. Mo
The LT285/75R16-size Toyo A/T Open Country tires have a 33-inch diameter. Rated as an eight-ply, load-range "D" truck tire, this rubber can carry up to 3305 pounds at each wheel when inflated to 65 psi for use on a fullsize truck. Note that tire pressures must be dropped considerably for use on a lightweight XJ Cherokee. American Racing's Mojave-series "ATX" 16x8-inch wheels and mounting hardware provide sensational looks and exceptional stamina to match these Toyo tires.
The LT285/75R16-size Toyo A/T Open Country tires have a 33-inch diameter. Rated as an eigh

The new look! This is one XJ Cherokee that has outstripped its urban grocery-grabber status. Full-Traction Suspension's system has transformed the formerly stock XJ into "Project Trail Runner." Toyo tires and American Racing wheels enhance appearance while providing a rugged match for the new suspension system. Next month's installation of new bumpers and a winch will take us one step closer to those rough trails.
The new look! This is one XJ Cherokee that has outstripped its urban grocery-grabber statu

Sources
American Racing Wheels 19067 Reyes Ave. S. Rancho Dominguez CA 90221 310-635-7806	Powertrain Industries 7532 Anthony Ave. Garden Grove CA 92841
Full-Traction Suspension 6951 McDivitt Dr. Bakersfield CA 93313	Toyo Tires 6261 Katella Avenue, Suite 2B Cypress CA 90630 8-00/-678-3250 www.toyo.com