I have a 1997 Jeep Cherokee XJ that I left stock for nearly 20 years. Since then, I’ve been building it into an overland Jeep for trips on Backcountry Discovery Routes, with a 3.5-inch OME lift from DPG Offroad.
This is the home for that Jeep: the repairs, the modifications, and what I’ve learned after living with them. The articles document work on one vehicle, often with photos of the awkward parts of the job. Where a part or an approach hasn’t worked out, I’ve added what changed and why.
The build, so far
The projects below cover a hidden winch behind the stock bumper, steering and brake work, transmission cooler lines, and smaller improvements to the wiring and cabin. Some articles describe parts I’ve since replaced, so check their updates before treating an older installation as a current recommendation.
A full list of the Jeep’s current modifications is still to come. For now, the individual project notes are the record of what I installed, how it fit, and how it held up.
Start here
Three projects with installation details and lessons from using the Jeep.
Machines · 2020
Jeep XJ Boostwerks Comp Mount Hidden Winch Installation
Installing a hidden Warn M8-S in my Jeep Cherokee
Machines · 2019
Jeep XJ Transmission Cooler Line Upgrade
Converting Jeep Cherokee transmission cooler lines to stainless-braided PTFE hose
Machines · 2019
Jeep XJ Brown Dog Motor Mounts Installation Notes
Installation notes and a 2026 update on vibration and replacement mounts
All Jeep articles
13 projects and guidesBodywork and recovery
Making room for a winch, carrying the spare, and repairing the body.
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Jeep XJ Boostwerks Comp Mount Hidden Winch Installation
Installing a Warn M8-S winch behind the stock Jeep XJ bumper with a Boostwerks hidden winch mount and reinforced steering box area.
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Jeep XJ Tire Carrier License Plate
Relocating a Jeep XJ license plate to an aftermarket tire carrier and wiring a durable illuminated mounting bracket.
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Jeep XJ Rear Quarter Panel Patching
Removing damaged Jeep XJ rear-quarter trim, fabricating small sheet-metal patches, and sealing the mounting holes left behind.
Steering and brakes
Parts, fitment, and installation notes from work on this XJ.
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Jeep XJ PSC Power Steering Replacement
Replacing a failed Jeep XJ power-steering pump with a PSC unit, including pulley fitment and the accessory-belt length that worked.
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Jeep XJ Teraflex Disc Brake Conversion
Converting a Jeep XJ rear axle from drum brakes to a Teraflex disc-brake kit, including fitment and installation notes.
Engine and drivetrain
Mounts, cooling lines, exhaust hardware, and throttle response, including long-term updates.
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Rebuilding a Jeep XJ Transmission Mount Exhaust Hanger
Rebuilding a discontinued Jeep XJ transmission-mount exhaust hanger with a reusable bracket and a replaceable rubber bushing.
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Jeep XJ Transmission Cooler Line Upgrade
Converting a Jeep XJ’s AW4 transmission cooler lines to -6 AN PTFE hose: parts, installation, sizing references, and a 15,000-mile update.
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Jeep XJ Brown Dog Motor Mounts Installation Notes
Brown Dog motor mount installation notes for a Jeep XJ, with a 2026 review update on harsh idle vibration and switching to Stinky Fab Racing mounts.
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Jeep XJ 62mm Throttle Body Upgrade
Installing a DW Designs 62 mm throttle body on a Jeep XJ 4.0-liter engine and documenting the resulting throttle response.
Electrical and cabin
Factory-style switches, heated mirrors, and the overhead compass.
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Jeep XJ Heated Side Mirror Upgrade
Retrofitting heated side mirrors on a Jeep XJ using compatible factory wiring, replacement glass, and model-year-specific connectors.
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How to Calibrate a Jeep XJ Overhead Console Compass
How to set the geographic variance zone and manually calibrate the factory overhead-console compass in a Jeep Cherokee XJ.
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Jeep XJ Illuminated Extended Idle Switch
Building an illuminated Jeep XJ extended-idle control from an OEM-style fog-light switch, custom labeling, and a relay.
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Jeep XJ Fog Light Wiring with OEM Rocker Switches
Wiring Jeep XJ fog lights through a five-switch panel built with new-old-stock OEM rocker switches and functional backlighting.


