Jeep Cherokee XJ Overland: Adventure On A Budget

Intrduction

Probably the most bang for your buck of any off-road vehicle available today is the overland four-door Jeep Cherokee XJ—especially for pure versatility. The classic, boxy, station wagon body style is unmistakable, especially because there were nearly 3 million built around the globe over the vehicle’s 18-year life span from 1983-2001.

Because of the long model life, high build volume, and the vehicle’s off-road prowess, there is huge aftermarket support for this vehicle today.

While these vehicles have proven their durability, you can also be confident that no matter where you travel you are sure to find readily available inexpensive replacement Jeep Cherokee XJ parts. Because of the age of the vehicle, they are also devoid of any computers, which makes them easy to work on whereever your adventures might take you.

“While these vehicles have proven their durability, you can also be confident that no matter where you travel you are sure to find readily available inexpensive replacement Jeep Cherokee parts.”

What Is the Jeep Cherokee XJ?

The XJ was the first non-military 4×4 with unibody construction, which paved the way for the small SUV and crossover craze we see today. Its stock 4.0L inline-six puts out 190 hp and 225 lb-ft of torque.

While not known for its power, the Cherokee is relatively lightweight and has enough grunt to carry a load, while traversing tough off-road terrain.

The AX-15 five-speed manual transmission provides the driver with the control needed to get the most out of the motor in all conditions.

Sub $450 Craigslist Story

Adam Schalow bought an unmodified red 1994 Jeep Cherokee 4-Door SE 4.0L I6-powered five-speed manual model off craigslist for $450, and built it into the overland adventuremobile you see here. Yep, this is a sub-$450 craigslist story.

The Jeep Cherokee came with a bad clutch and the common rust issues that these vehicles have a reputation for, but Schalow is a mechanic and was able to address those issues himself.

The rust, a continual battle, was the major repair when purchased and quite the job, as it required welding in new floorboard patch panels from a donor XJ from the muffler all the way to the tailgate above the passenger side framerail.

The idea behind this build was to create a comfortable, capable, easy to fix and inexpensive to keep on the road overland vehicle that could be completely self-sufficient and off the grid for up to seven days.

At First Sight

Schalow’s passion for the Jeep Cherokee runs in the family, and started at an early age. His first experience with the overland jeep XJ was at age 8 when his father brought home a brand-new 1991 Laredo model.

He and his father loved it so much that when Schalow turned 16, with a fresh driver’s license in hand, his father bought him a 1992 Country model.

Schalow was so excited to have his own new Jeep Cherokee that he spent that first night sleeping in it, sprawled across the back seat while parked in the driveway.

He built that vehicle into a well-equipped rock crawler, but sold it five years later, as his interests shifted toward the world of sports cars.

Fast-forward to June 2015 when Schalow was on the hunt for a VW Westfalia Bus to enter the world of overland travel. While on the hunt for the bus, he came across the craigslist ad for this overland jeep XJ, and it was love at first sight.

Cost-Conscious Mods That Actually Work

Everything on Schalow’s off-road vehicle build is done with cost and function in mind. Each dollar saved on the build is another dollar that can be spent searching for adventure on the road less traveled. Schalow stuck with the stock XJ wheels, both for their “utilitarian” looks and cost savings.

He was able to modify a $75 Amazon special snorkel to work with the stock airbox, and mounted two $20 LED Amazon light pods in the front bumper, which he sealed up with RTV for better moisture resistance.

Sure these aren’t the highest performance or most durable products, but they get the job done, can be replaced easily and are incredibly inexpensive.

Schalow found a great used deal on a Rough Country 3-inch lift and three Nexen Roadian MT (31×10.5R15) tires, which only had 800 miles on them.

The entire lift kit has since been upgraded to higher-quality parts, which offer up a much better ride.

He loves the tires off-road, but only gives them a 2.5 out of 5 star rating for on-road use, and says they are nearly impossible to balance properly on his wheels. Perhaps it’s his wheels or something the previous owner did to the tires, he can’t be sure.

Built For Function

The 4×4 capabilities of this Jeep XJ are improved with a few other key parts as well.

The Rusty’s Front Bumper offers up a winch mount, which houses a Warn M-8000 with Rugged Ridge synthetic line and utilizes a Southeast Overland hawse fairlead.

Its rear bumper is a custom-made unit, which utilizes a trailer ball hitch coupler to secure the spare tire swing out and lockable double jerrican holder.

The radiator was upgraded to a Mopar HD unit, to keep the XJ running cool in the 100-degree Virginia summer heat, where Schalow lives.

The front axle is a stock D30 with a Lockright Locker, while the rear is a non C-clip D35 out of a 1986 XJ, with 4.10 gears and a Lockright Locker.

Its brake lines were also extended at all four corners, to work with the 3-inch lift, and the headlights were upgraded to improve nighttime visibility.

For even greater off-road prowess, Schalow recommends adding adjustable lower control arms—readily available from a range of manufacturers, or as used takeoffs from similar Jeep models.

These allow for better suspension geometry and durability, especially on rough trails. Another highly recommended upgrade is a set of anti-roll bar disconnects for the front suspension. 

Schalow prefers quick-release units, like the JKS Swaybar Disconnects, for their easy operation and proven reliability. A clever feature is the included stem, which lets you stow the sway bar up and out of the way when disconnected, maximizing wheel articulation when tackling technical terrain. 

When the trail gets tough, Schalow can also disconnect the front sway bar to get maximum wheel articulation.

Living Quarters: Comfort on a Budget

Since this Jeep Grand Cherokee is Schalow’s home away from home, when he’s on the road chasing adventure, it has all the creature comforts that you’d expect around the house.

Most of the interior camping systems are based around a custom-built wooden platform system that houses much of the equipment, and doubles as a sleeping platform.

At the rear of the vehicle is a full kitchen setup that has a 31-quart Dometic drawer–style fridge and a heavy-duty slide out that holds a propane Coleman grill and a stainless Houzer sink.

Always keeping a cold drink within reach, a Dometic 10.5-quart freezer is installed between the front seats.

Making that work was no small task, as the stock console needed to be removed, the stock E-brake hole was welded up and a foot pedal E-brake system out of a Jeep Comanche needed to be installed.

“While not known for its power, the Jeep Cherokee is relatively lightweight and has enough grunt to carry a load while traversing tough off road terrain.”

Just because it was built on a budget doesn’t mean that it’s devoid of some luxury Jeep accessories.

This overland jeep XJ even has a custom pressurized hot water shower system, which utilizes a 10.6-gallon Front Runner water tank, 1/2-inch PEX plumbing, 12V Shur-Flo RV water pump, a Duda Diesel heat exchanger, and a Phoenix exterior RV lockable shower box.

All the electrical needs are handled with a dual battery system, which utilizes one deep-cycle AGM battery and is charged through portable Overland Solar panels and a Blue Sea charge relay/battery isolator.

A Blue Sea ST Blade fuse block is used to handle the power needs of all the vehicle’s accessories.

Atop Schalow’s XJ is a roof top tent (RTT) and awning, mounted to two Thule gutter mount crossbars. The RTT is a 1998 Camping Lab model that Schalow picked up used, which offers up a comfortable 3-inch foam mattress and an optional full annex, which is equally great to escape the weather and use as a shower room.

The awning is a Foxwing unit by Oztent/Rhino Rack and offers 270 degrees of coverage around the vehicle.

Future Plans and Big Adventures

Schalow has grandiose plans for both this build and the places it will take him. The next vehicle upgrade will be a new motor, as the current one has some internal noises, is showing signs of compression issues in one of the cylinders, and has the occasional puff of blue smoke.

Smaller upgrades for capability and ease of use will also be addressed, like adding rock, backup, and awning lighting.

Schalow thinks big, and plans to tackle a full custom Westfalia-type pop-top roof on the XJ himself, which will allow him to still sleep up high on the vehicle while also allowing him to mount kayaks and mountain bikes to the roof.

“Everything on Schalow’s off-road vehicle build is done with cost and function in mind. Each dollar saved on the build is another dollar that can be spent searching for adventure on the road less traveled.”

For Schalow’s next overland Jeep XJ adventure, he is hoping to take a six- to eight-week trip from Virginia all the way to southern Baja and back. First heading west to Southern California then down the Baja peninsula before coming back via ferry to mainland Mexico and meandering back to the East Coast.

For more info on Schalow’s adventures in his Jeep Cherokee XJ be sure to follow him on Instagram @Overland_History. Besides fun photos of the XJ in interesting locations, you’ll also learn a ton about the history of the places Schalow visits.

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1994 Jeep Cherokee XJ Overland Upgrades

Wheels & Tires:

• Stock XJ wheels wrapped in 31×10.5R15 Nexen Roadian MTs

Running Gear:

• 4.10 Yukon Gear front and rear
• Powertrax Lock-Right Lockers front and rear

Suspension:

• 3.5-inch Rubicon Express coil and leaf spring lift kit with adjustable Trackbar
• Bilstein 5100 Series shocks

Under The Hood: 

• Mopar HD radiator
• Duda 20-plate heat exchanger
• Top Gear Automotive headlights with H4 bulb upgrade
• Flowmaster 40 series after-cat exhaust

Armor:

• Rusty’s Front Trail bumper
• Custom rear bumper with tire and double jerrican holders

Off-Road Accessories:

• Warn M-8000
• Rugged Ridge Synthetic winch line
• Southeast Overland Hawse Fairlead
• Rough Country sway bar disconnect
• Nilights Floodlight Pods

Overland Accessories:

• Camping Lab RTT
• Foxwing awning
• Thule roof rack
• Overland Solar 90-watt portable panels
• AGM deep-cycle battery
• Blue Sea Charge Relay
• Blue Sea ST Blade fuse block
• Custom 10.6-gallon Onboard Hot Water Shower System
• Dometic 31-quart Drawer Fridge
• Dometic 10.5-quart Console Freezer
• Custom sleeping platform/storage system
• Coleman propane grill
• Houzer stainless sink
• Blue Ridge Overland Gear seat-mounted organizational system
• Blue Ridge Overland Gear spare tire storage bag

FREQUENTLY ASKED QUESTIONS

What were the later uses of the 4.0-liter engine after the Cherokee went out of production?

After the Cherokee ceased production, the notable 4.0-liter engine found continued life in subsequent vehicle models. Its journey did not end with the Cherokee; it was incorporated into the TJ Wrangler, remaining a trusted component until 2006.

However, the transition wasn’t met without some discontent. When the 4.0-liter was eventually replaced by a less remarkable 3.8-liter V-6, many enthusiasts expressed their disappointment, lamenting the loss of a beloved engine that had earned its reputation for reliability and performance.

Key Points:

• The 4.0-liter engine was utilized in the TJ Wrangler until 2006.
• It was replaced by a 3.8-liter V-6, which did not receive the same level of acclaim.
• Jeep fanatics mourned the end of the 4.0-liter era due to its esteemed performance and reliability.

This shift marked the end of an era for a powerhouse engine that had garnered respect and admiration from a dedicated community.

How did the Cherokee’s engine evolve to gain its current status?

The evolution of the Cherokee’s engine is a tale of transformation from modest beginnings to iconic status. Initially, when the vehicle appeared in 1984, it was powered by an engine that offered a mere 110 horsepower. While this might have been sufficient for the era, the powertrain left much to be desired for enthusiasts seeking robust performance.

Key Evolution Milestones:

1. 1987 Update: Introduced a 4.0-liter inline-six engine, significantly boosting horsepower to 173. This change transformed the Cherokee from a simple utility vehicle to a more powerful and versatile option suited for both daily driving and adventurous escapades.
2. Unibody Construction: Unlike its competitors with body-on-frame construction, the Cherokee incorporated a unibody design. This modernized the SUV and provided a more comfortable ride without compromising ruggedness.
3. Solid Axles: Despite the advanced unibody design, the Cherokee retained solid axles. This blend of old and new technology allowed it to maintain off-road capabilities while improving on-road driving dynamics.

Market Impact:

The combination of the upgraded engine and innovative construction techniques helped elevate the Cherokee’s status. It became an American SUV icon, appealing to mainstream consumers and off-road aficionados alike. This balance between accessibility and ruggedness ensured its lasting legacy as both a popular choice and a cult classic.

In essence, the transition from a modest 110-horsepower engine to a more potent 173-horsepower inline-six was pivotal. It redefined what the Cherokee could do, turning it into a symbol of American automotive ingenuity and adventure.

How does the 4.0-liter engine compare to the engines available before 1987?

The 4.0-liter engine stands out as a major improvement compared to the engines available before 1987. Earlier models featured less powerful options: a 2.5-liter four-cylinder, a 2.8-liter V-6, and a 2.1-liter turbo-diesel.

Key differences include:

• Power: The 4.0-liter engine delivers a substantial boost in horsepower, with the high-output version reaching 190 horsepower by 1991. This is a significant upgrade from the less powerful engines of previous models.
• Torque: Known for its torque, the 4.0-liter engine offers better performance, especially in demanding driving conditions.
• Durability: The 4.0-liter engine is renowned for its durability and reliability, standing up to rigorous use far better than its predecessors.

In summary: The 4.0-liter engine not only provides more power and torque but also offers a robust and dependable option, making it a vastly superior choice compared to the engines available before 1987.

What price range can you expect for used Jeep Cherokees?

Adam Schalow bought an unmodified red 1994 Jeep Cherokee 4-Door SE 4.0L I6-powered five-speed manual model off Craigslist for $450, and built it into the overland adventuremobile you see here. Yep, this is a sub-$450 Craigslist story.

But what can you generally expect to pay for a used Jeep Cherokee? Prices are all over the place, ranging from $1,000 for high-mileage, trail-worn rigs to over $30,000 for low-mileage, pristine, unmodified examples. Most Cherokees on the market are far from pristine, and prices reflect that. On average, you can expect to spend around $5,000 for a decent one.

So, while Adam’s story is a remarkable find, it’s essential to know the broader market spectrum when hunting for your own Jeep Cherokee adventuremobile.

What are common problem areas in the Jeep Cherokee?

The Jeep Cherokee came with a bad clutch and the common rust issues that these vehicles have a reputation for, but Schalow is a mechanic and was able to address those issues himself.

The rust, a continual battle, was the major repair when purchased and quite the job, as it required welding in new floorboard patch panels from a donor XJ from the muffler all the way to the tailgate above the passenger side framerail.

However, rust and clutch problems aren’t the only concerns with the Cherokee. The part-time four-wheel-drive system’s vacuum-operated front-axle engagement can fail, leaving you stranded or worse. Additionally, the 4.0-liter engine’s rear main seal is notorious for developing leaks.

For models produced before 1997, the rear hatch was made of fiberglass, which is prone to cracking. Another significant issue arises from ill-advised modifications.

Be cautious of Cherokees with suspension lifts and larger tires. Even a modest three-inch lift can alter the rear driveshaft angle enough to shear the U-joints, and the Cherokee’s light-duty axles aren’t built to handle oversized tires.

In summary, while the Cherokee is a robust vehicle, it has its share of common problem areas. Whether it’s dealing with rust or navigating the pitfalls of drivetrain and engine issues, being aware of these potential problems can save time and money in the long run.

Where to find Jeep XJ Overland suspension lift kits?

For a budget-friendly build, many owners look for used deals on Rough Country kits via platforms like Craigslist. This build uses a 3.5-inch Rubicon Express lift kit with Bilstein 5100 shocks, which improve ride quality and off-road control. Lift kits like these are available from Jeep aftermarket brands, off-road parts retailers, and even used Jeep parts sellers, since many owners upgrade or sell their take-off kits.

Which tires work best for Jeep XJ overlanding?

This Jeep XJ runs Nexen Roadian MT 31×10.5R15 tires. These tires provide strong traction on dirt, mud, and rocky trails while still fitting well on stock XJ wheels. For overlanding, 31-inch all-terrain or mud-terrain tires are a great balance between off-road capability, durability, and drivability.

What roof rack is best for a Jeep XJ Overland build?

The Jeep XJ has rain gutters along the roof, which makes Thule gutter-mount crossbars an excellent roof-rack option. This build uses those crossbars to support a Camping Lab rooftop tent and a Foxwing 270-degree awning. Gutter-mount racks are popular because they don’t require drilling, are easy to install, and provide strong support for tents and gear.

What overland accessories does this Jeep XJ have?

This Jeep XJ is equipped with a wide range of accessories designed for extended off-grid travel:

Camping & Living:

• Camping Lab rooftop tent
• Foxwing 270-degree awning
• Custom sleeping and storage platform
• Dometic 31-quart Drawer Fridge
• Dometic 10.5-quart Console Freezer
• Coleman propane grill
• Stainless steel sink

Power & Electrical:

• Dual-battery AGM system
• Portable solar panels
• Battery isolator
• Fuse block for accessories

Water & Comfort:

• 10.6-gallon onboard water tank
• Pressurized hot-water shower
• RV water pump and heat exchanger
• Exterior shower box

Off-Road & Recovery:

• Warn winch
• Synthetic winch rope
• Heavy-duty front and rear bumpers
• Sway-bar disconnects
• LED auxiliary lights

Together, these accessories allow the Jeep XJ to function as a fully self-contained overland vehicle capable of spending multiple days off-grid.