Jeep XJ 65 Lift: Easy Installation Guide

Jeep Xj 65-piece Lift Install Guide: Elevate Your Ride With Ease

The Jeep Cherokee XJ is a legend. For years, it’s been a favorite among off-road enthusiasts and daily drivers alike.

Its compact size, rugged build, and legendary four-wheel-drive system make it incredibly capable. But for many, the desire to go bigger, to tackle tougher trails, and to give their XJ a more aggressive stance is strong.

That’s where a lift kit comes in. Installing a lift kit can transform your XJ, offering better ground clearance, improved suspension travel, and the ability to fit larger tires.

This guide focuses on the Jeep XJ 65-piece lift install. This specific kit is designed to provide a significant upgrade, offering a comprehensive package that addresses many aspects of the suspension system. While the idea of a 65-piece kit might seem daunting, it’s actually designed to be a thorough solution, ensuring that when you lift your XJ, you’re doing it right, with the necessary components for a balanced and durable setup. We’ll break down the process, highlight key components, and offer tips to make your installation as smooth as possible. Remember, patience and attention to detail are your best friends when tackling a project like this.

Understanding Your 65-piece Lift Kit

A 65-piece lift kit for a Jeep XJ isn't just about slapping taller springs on. It’s a carefully curated collection of parts designed to work together to improve your vehicle's off-road performance and on-road manners.

This extensive kit typically includes not only the primary lifting components like springs and shocks but also a host of supporting hardware that ensures proper alignment, articulation, and durability.

The sheer number of pieces suggests a complete overhaul of the suspension geometry. This often means components like adjustable control arms, track bars, sway bar links, and potentially even brake line extensions or transfer case drop kits.

Each piece plays a crucial role in maintaining the vehicle's stability and safety after the lift is applied.

Without these supporting components, a simple spring lift can lead to poor handling, premature wear on other parts, and even dangerous driving conditions. This comprehensive approach is what sets a more involved kit apart and ultimately leads to a better-performing, longer-lasting modification.

Preparation Is Key: Tools And Safety First

Before you even think about touching a wrench, proper preparation is paramount. This isn’t a quick bolt-on job; it requires time, space, and the right equipment.

Essential Tools:

• Jack and Jack Stands: You’ll need a robust floor jack capable of lifting your XJ and at least two heavy-duty jack stands to support the vehicle safely. Never work under a vehicle supported only by a jack.
• Socket Set and Wrenches: A comprehensive set of metric sockets and wrenches is essential. You’ll encounter various bolt sizes, so having a full range from small to large is crucial.
• Torque Wrench: Essential for tightening critical suspension components to the manufacturer’s specifications. Overtightening or undertightening can lead to failure.
• Pry Bars and Hammers: These will be invaluable for separating old suspension components and persuading new ones into place.
• Penetrating Oil: For loosening stubborn, rusted bolts. Apply generously and let it soak.
• Wire Brush: To clean rust and debris from mounting surfaces and bolt threads.
• Grease Gun and Grease: For lubricating new components and zerks.
• Safety Glasses and Gloves: Protect your eyes and hands from dirt, rust, and potential hazards.
• Wheel Chocks: To prevent the vehicle from rolling.

Safety Precautions:

• Park on a Level Surface: Ensure your XJ is on a flat, stable surface.
• Engage Parking Brake and Chock Wheels: Even on a level surface, this is a non-negotiable safety step.
• Disconnect Battery: For safety, especially when working near electrical components.
• Follow Torque Specs: This cannot be stressed enough. Refer to your kit’s instructions and a reliable Jeep XJ service manual for precise torque values.
• Work Methodically: Don’t rush. Double-check each step. If something feels wrong, stop and reassess.
• Get a Helper: A second pair of hands makes the job significantly easier and safer.

Step-by-step Installation Guide: A Comprehensive Breakdown

Installing a 65-piece lift kit is a multi-stage process. While specific kits may vary slightly, the general order of operations and the types of components addressed remain consistent.

1. Front Suspension Disassembly

This is where you begin to dismantle the existing front suspension. The goal is to remove all components that will be replaced by the new lift parts.

• Remove Front Wheels: Loosen lug nuts while the vehicle is on the ground, then jack up the front and remove the wheels.
• Disconnect Shocks: Unbolt the upper and lower mounts of the front shocks.
• Disconnect Sway Bar Links: These connect the sway bar to the control arms or axle.
• Disconnect Track Bar: This is a crucial component that prevents the axle from shifting side-to-side. It’s usually bolted at both the axle and the unibody frame.
• Support the Axle: Use your jack to support the front axle once the shocks and track bar are loose.
• Remove Coil Springs: Carefully lower the axle enough to remove the old front coil springs. Be aware that they are under tension.
• Disconnect Control Arms: Unbolt the upper and lower control arms from both the axle and the unibody frame. This will allow the axle to be fully lowered or removed if necessary.

2. Front Suspension Component Installation

With the old parts out, it’s time to install the new, lifted components.

• Install New Control Arms: If your kit includes new control arms (often adjustable), install them now. Ensure they are oriented correctly and loosely bolted. Adjustable arms allow for fine-tuning caster and pinion angles later.
• Install New Coil Springs: Place the new, taller coil springs into their seats on the axle and unibody. You might need to use your jack to compress them slightly to get them seated properly.
• Install New Shocks: Mount the new, longer shocks at their upper and lower mounting points.
• Install New Track Bar: If your kit includes a new or adjustable track bar, install it now. An adjustable track bar is critical for recentering the axle after a lift, preventing the dreaded “dog-tracking” effect.
• Install New Sway Bar Links: Connect the new, often longer, sway bar links. Some kits might include quick disconnects for enhanced articulation off-road.
• Install Steering Stabilizer (if included): Many lift kits come with a new steering stabilizer to help dampen steering wheel shimmy and improve handling. Mount this according to the kit’s instructions.

3. Rear Suspension Disassembly

The rear suspension on an XJ is typically simpler than the front, but requires similar care.

• Disconnect Rear Shocks: Unbolt the upper and lower mounts of the rear shocks.
• Disconnect Sway Bar Links (if applicable): Some XJs have rear sway bars.
• Support the Rear Axle: Use your jack to support the rear axle.
• Remove Rear Leaf Springs or Coil Springs: Depending on your XJ’s original setup (leaf springs are common on older models, coils on later ones, or aftermarket replacements), you’ll need to unbolt and remove them. This often involves dealing with U-bolts and spring plates.
• Disconnect U-bolts and Spring Plates: Loosen and remove the U-bolts that hold the rear axle to the leaf springs. Remove the spring plates.

4. Rear Suspension Component Installation

Similar to the front, install the new lift components in the rear.

• Install New Leaf Springs or Coil Springs: Fit the new, taller springs. If using leaf springs, ensure all components (e.g., bushings, center pins) are correctly placed.
• Install New Shocks: Mount the new, longer rear shocks.
• Install New U-bolts and Spring Plates: Secure the axle to the new springs using the new U-bolts and plates provided in the kit. Torque these to spec.
• Install Rear Sway Bar Links (if applicable): Reconnect or install new rear sway bar links.

5. Additional Components And Adjustments

This is where the “65-piece” aspect really comes into play, addressing many other aspects of the suspension and drivetrain.

• Transfer Case Drop Kit: Lifting an XJ can alter the angle of the transfer case output shaft, potentially causing vibrations. A transfer case drop kit lowers the transfer case slightly to correct this angle. Install the spacers and longer bolts as instructed.
• Brake Line Extensions: The increased axle droop can put strain on the stock brake lines. Most kits include longer brake line brackets or extensions to prevent them from stretching or breaking. Mount these securely.
• Bump Stops: The lift kit will likely include extended bump stops. These prevent the suspension from compressing too far, which could cause tire-to-fender contact or damage to suspension components. Install these at their designated mounting points.
• Miscellaneous Hardware: This is where the bulk of the 65 pieces come in. It includes things like new bushings, washers, nuts, bolts, brackets, and any other small parts needed for a complete installation. Ensure every piece from the kit is accounted for and installed according to the instructions.
• Alignment: After all suspension components are installed and bolted down, it is absolutely critical to get a professional four-wheel alignment. The lift kit significantly changes the suspension geometry, and an alignment will ensure proper caster, camber, and toe settings for safe driving and even tire wear.

6. Final Checks And Lowering The Vehicle

Before hitting the road, a thorough final inspection is essential.

• Double-Check All Fasteners: Go back over every bolt and nut you tightened. Ensure they are all torqued to specification. Pay special attention to critical components like control arms, track bar, and U-bolts.
• Inspect for Clearance: Check that no suspension components are binding or making contact with the chassis or other parts. Ensure brake lines are routed correctly and have enough slack.
• Lower the Vehicle: Carefully lower the XJ off the jack stands.
• Torque Lug Nuts: With the vehicle weight on the wheels, torque the lug nuts to the manufacturer’s specification in a star pattern.

Key Components Explained: What Makes Up The 65 Pieces?

Understanding the purpose of the various components within a comprehensive lift kit is crucial for a successful installation and a well-performing vehicle. Here’s a look at some of the most common, and often numerous, parts you’ll find in a 65-piece XJ lift kit:

1. Coil Springs: These are the primary lifting components. Taller and often stiffer than stock, they raise the vehicle’s ride height.

2. Shocks: Longer shocks are required to accommodate the increased suspension travel and height. They are tuned to work with the new springs.

3. Control Arms: These locate the axle relative to the chassis. Adjustable control arms allow for precise alignment adjustments after lifting, correcting caster and pinion angles.

4. Track Bar (Panhard Rod): This bar prevents the axle from shifting side-to-side. An adjustable track bar is essential for centering the axle under the vehicle after a lift, especially on the front.

5. Sway Bar Links: These connect the sway bar to the suspension. Longer links are needed for a lift, and some kits include quick-disconnects for off-road use.

6. U-Bolts and Spring Plates: These secure the rear axle to the leaf springs. New, longer U-bolts are typically included with lift kits that modify the rear spring setup.

7. Bump Stops: These limit suspension compression to prevent damage and tire contact. Extended bump stops are crucial for lifted vehicles.

8. Brake Line Brackets/Extensions: To prevent brake lines from stretching or breaking due to increased axle droop, extensions or relocation brackets are provided.

9. Transfer Case Drop Kit: This kit lowers the transfer case to correct the driveshaft angle and reduce vibrations caused by the lift.

10. Bushings and Hardware: This category accounts for a significant portion of the “pieces.” It includes all the necessary nuts, bolts, washers, and rubber or polyurethane bushings required to mount all the new components securely.

11. Steering Stabilizer: While not always part of every kit, many comprehensive kits include a new steering stabilizer to improve steering feel and reduce bump-steer.

12. Leaf Spring Bushings: If your kit involves leaf springs, new bushings for the spring eyes and shackles are vital for proper flex and longevity.

13. Shackles (Rear): Some rear lift solutions involve longer shackles, which are the links connecting the leaf spring ends to the chassis.

14. Shackle Relocation Brackets: These can be used in conjunction with or instead of shackles to achieve lift and improve shackle angle for better flex.

15. Hardware for Mounting: This includes specialized brackets for track bars, sway bars, and brake lines, along with all the necessary fasteners.

16. Leaf Spring Liners/Inserts: For kits that utilize existing or modified leaf springs, these can be included to reduce noise and improve ride quality.

17. Center Pins: For leaf spring setups, new center pins are often required to properly locate the axle under the new spring pack.

18. Shock Mounting Hardware: Brackets, nuts, and bolts specifically designed for mounting the new, longer shocks.

19. Sway Bar Relocation Brackets: Sometimes needed to maintain proper sway bar geometry after a lift.

20. Greases and Lubricants: Some kits may include specialized greases for bushings or zerks.

Common Pitfalls And How To Avoid Them

Even with a detailed guide, DIY lift installations can present challenges. Being aware of common mistakes can save you time, frustration, and potentially costly repairs.

• Incorrect Torque: This is perhaps the most common and dangerous mistake. Bolts that are too loose can lead to component failure, while over-tightened bolts can strip threads or break. Always use a torque wrench and follow the specifications provided by the lift kit manufacturer and your Jeep’s service manual.
• Forgetting the Alignment: Lifting your Jeep drastically alters its suspension geometry. Driving without a proper alignment can lead to poor handling, excessive tire wear, and a vehicle that pulls to one side. Schedule an alignment immediately after completing the installation.
• Ignoring the Transfer Case Drop: The change in driveshaft angle after a lift can cause vibrations, especially at certain speeds. Failing to install a transfer case drop kit (if recommended for your lift