1990 Cherokee Project: Stage 3 |
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Specifications: |
Cherokee History: In 1993 I decided my CJ-7 was not a “Street Jeep.” The air conditioning had no hope of cooling the passenger compartment. The heater and defroster were inadequate during the winter months and there was never enough space. So I sold the CJ-7 and bought a Cherokee. I built the Cherokee into what I consider a “Stage Three" 4x4: a vehicle that will perform well off the highway but could still be an everyday vehicle. By this I mean the Cherokee can consistently run the "Most Difficult" trails when needed but takes you there in comfort and with reasonable fuel economy. And believe me; I know how to push a vehicle to its limits. Why a Cherokee? I like the body style, Fuel Injected motor (4.0L), and automatic
transmission. I don't like the unibody, but I'll live with it to get the other
features. Just as a side note: the 1997+ Cherokees have a much stiffer unibody
which should hold up better to off road abuse. Note: This Cherokee was stolen in May 1997. I hope the recipient of this fine vehicle appreciates the effort that went into building such a vehicle. I have a few other thoughts which I will keep to myself. |
Component Sources |
| 1990 CHEROKEE: | DON-A-VEE JEEP (562) 867-7256 - (714) 528-5337 - (800) 366-JEEP www.donavee.com |
| SEATS: | VISION RESEARCH out of business |
| SUSPENSION: OFF ROAD GENERAL STORE | (949) 770-9300 www.offroadgs.com |
| WELDER: 190 amp | Premier Power Welder (800) 541-1817 - (970) 963-8875 www.premierpowerwelder.com tell them Sidekick referred you and you'll receive free shipping. |
| TIRES: 31x11.50x15 AT/S | Goodyear (800) GOODYEAR www.goodyear.com |
| WHEELS: AR-36, 7x15" | American Racing (310) 635-7806 - (800) 959-1969 www.americanracing.com |
| REAR AXLES: Dana 44, 4:10, ARB | Tri-County Gear--built it! (909) 623-3373 ARB Air Locker--locked it up! (888) 427-2872 www.tricountygear.com |
| FRONT AXLES: Stock Dana 30, 4:10, TrueTrac | Tractech--builds TrueTrac! (800) 328-3850 Tractech also builds Detroit Lockers www.tractech.com |
| SPARE TIRE & CAN RACK: | Canyon City (out of business) |
| TRANSFER CASE: | Currie Enterprises (Shorting Kit) (714) 528-6957 www.currieenterprises.com |
| REAR STORAGE BOX | Tuffy Products (800) 328-3850 www.tuffyproducts.com |
| OFF HIGHWAY LIGHTS: Pro 80s | PIAA Corp. (800) 525-7422 www.piaa.com |
| CUSTOM FUEL TANK: 33 Gallons | Aero Tanks (909) 737-7878 www.aerotanks.com |
| WINCH: 8000i | Warn Industries (800) 543-9276 www.warn.com |
| DRIVE LINES | Tom Wood's Custom Drive shafts (877)
4974238 www.4xshaft.com |
| HOT WATER SHOWER | R&M Specialty Products (707) 838-3869 |
| CUSTOM REAR SPRINGS | National Spring Co. (619) 441-1901 |
| SHOCKS: RS 9000 W/REMOTE | Rancho Suspension (310) 630-0700 www.gorancho.com |
| DUAL QUICK AIR COMPRESSORS | Sun Performance (949) 588-8567 www.sunperformance.com |
| AIR FILTER | K&N (714) 684-9762 www.motorville.com/kn_home/kn.html |
| STEERING MODIFICATIONS | Off Road General Store (949) 770-9300 www.offroadgs.com |
| MAX MULTI-PURPOSE TOOL | Forrest Tool Company (707) 937-2141 |
| HI-LIFT JACK |
Hi-Lift Jack Company (812) 384-4441 - (800) 233-2051 www.hi-lift.com |
OTHER ACCESSORIES BUILT OR ASSEMBLED By Rick Russell Roof Rack Onboard air compressor with tank
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| I bought a high mileage 1990 Cherokee from Don-A-Vee Jeep in Placentia, CA. If I was going to do it again, I would buy a 1991 or newer. These motors have more horsepower. |
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The Vision Research seats were the best seats I could find. The suspension system on these seats was incredible. Unfortunately this company is out of business. Refer to our AJ-8 for information about Beard Seats. |
| The Kenwood 733A ham radio controls were installed in the ash tray slot. The main body of the radio was installed on the rear side panel across from the original tire mount. The CB is installed facing up, on the passenger's side of the center console. |
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Used two Quick Air compressors to pump air into the rear bumper which was sealed and used as a storage tank. |
| Tri-County Gear in Pomona installed a complete Dana 44 rear end with an ARB locker. They also changed the front gear ratio and installed a TrueTrac (limited slip). This combination worked perfectly for trail and street. |
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Did you ever wonder why 4-wheelers change the stock differentials to a Dana 44 or a Ford 9 inch? Check out the difference in brakes: 9.5" to 11" plus the Dana 44 brake shoes are wider. |
| The stock model 35 axle is too weak for any real abuse (left picture). So the complete differential was changed to a Dana 44 (right). |
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Both the rear bearings and rear axles are bigger in a Dana 44 than the original Model 35. |
| Currie Enterprises makes a transfer case shortening kit which will extend your driveshaft 4" and allow you to replace the slip yoke with a bolt-on style drive line. This also allows you to run your vehicle without a rear drive line. Otherwise the transfer case oil will run out after the slip yoke is taken out. |
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The custom built bumper held the Warn 8000i winch and PIAA Pro 80 lights. The bumper was built by Nairobi in Goleta, CA (Bulletproof Mfg. has taken over some of this business: (805) 967-2005) www.bulletproofmfg.com |
| Off Road General Store trimmed the front fenders after the new front Nairobi bumper was installed. |
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JKS disconnects were used to allow for a quick disconnect of the front sway bar while off roading. You can also see the aluminum spacer that Off Road General Store uses to add lift to the Rancho Lift Kit springs. In total the vehicle sat 5" higher than stock. |
| The Confer rack is basically a starter kit. I welded the two pieces together, welded expanded metal for a bottom, welded angle iron along the front and back to reinforce the expanded metal, welded the roof railing brackets together and then welded tabs for the radio antennas. When it was completely assembled, the rack was sand blasted and powder coated. Somebody should make a completed rack. |
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Off Road General Store had figured out how to change the ends of the Rancho 9000 shocks to a more common end. This allow them to access a wider range of shock lengths for a custom vehicle. |
| Did you ever notice the rear quarter panel on a stock Cherokee? If it has been wheeling much, it is bent. I bent mine on an easy trail within the first 3 months I owned the vehicle. The fix is easy: trim it up (right picture). |
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Exotic Body Works trimmed up the rear quarter panels and welded a plate across the bottom to keep the water out. I never hit it again. |
| National Spring in Cajon, CA built the custom rear springs to match the front height and carry the weight. A Tuffy box full of stuff and a Canyon City Tire Rack complete with two cans and Hi-Lift Jack overloaded the stock springs in a hurry. |
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The R&M Hot Water Shower and a Premier Power Welder were installed under the hood. I got plenty of use out of both of them. |
| Canyon City welded their tire rack to my bumper. I noticed they are now producing their own bumper with the mounting for the their tire rack already welded on. This would be my choice for a rear bumper next time. |
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The Tuffy rear storage box makes it easy to keep all the items neat that you need to carry when you leave the pavement. |
| This picture shows the Canyon City tire rack and the new 34 gallon Aero Tank. The new tank has a skid plate welded on it and is made of much better material. |
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Aero Tank has several tanks available for the Cherokee or they will build what ever you want. |
| Off Road General Store makes the best rocker panel protection I've seen. A lower bar protects the undercarriage while the upper double-bent tube protects the door. |
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The lower control arms were changed in conjunction with the lift kit. The picture shows a stock arm at the top. Off Road General Store provided the new lower arm which keeps the geometry correct at the new height. It was not necessary to change the upper control on my vehicle. |