Unleash the Beast: Your Definitive Guide to Choosing the Best XJ Long Arm Kit

Unleash the Beast: Your Definitive Guide to Choosing the Best XJ Long Arm Kit Lmctruck.Guidemechanic.com

The Jeep Cherokee XJ isn’t just a vehicle; it’s an icon, a canvas for adventure, and for many, a way of life. Known for its legendary reliability and robust unibody construction, the XJ has earned its place in off-road history. But let’s be honest: while stock XJs are capable, their full potential truly awakens with the right modifications. If you’re serious about taking your XJ’s off-road performance, ride quality, and overall capability to the next level, then a long arm suspension kit isn’t just an upgrade – it’s a transformation.

Welcome, fellow Jeep enthusiast, to the ultimate deep dive into the world of XJ long arm kits. As an experienced off-roader and someone who’s spent countless hours wrenching on these incredible machines, I understand the thrill of pushing your XJ to its limits. This comprehensive guide is designed to cut through the noise, providing you with all the essential knowledge, pro tips, and detailed insights you need to confidently choose the best XJ long arm kit for your specific needs. Get ready to unlock the true beast within your Cherokee!

Unleash the Beast: Your Definitive Guide to Choosing the Best XJ Long Arm Kit

What Exactly is a Long Arm Kit for Your XJ? The Foundation of Off-Road Dominance

Before we dive into the "best," let’s clarify what a long arm kit actually is and how it fundamentally differs from the factory setup or a typical short arm lift. In essence, a long arm kit replaces your XJ’s shorter factory control arms with significantly longer ones, relocating their frame-side mounting points further back on the chassis.

These longer control arms, typically spanning 30 inches or more, are connected to new, heavy-duty frame crossmembers. The primary goal of this design is to drastically reduce the operating angles of the control arms, especially when your suspension cycles through its full range of travel. Imagine a longer lever; it requires less effort to move something a certain distance, and that’s precisely the principle at play here.

The kit usually includes a new, robust crossmember that acts as the anchor for these longer arms, often providing additional structural rigidity to the unibody. Depending on the manufacturer, it might also incorporate transmission mounts, skid plates, and even integrated sway bar mounts. This intricate design is critical for achieving the performance benefits that make long arm kits so desirable for serious off-roaders.

Why Upgrade to a Long Arm Kit? Unlocking Your XJ’s True Potential

Upgrading to a long arm kit isn’t just about lifting your XJ higher; it’s about fundamentally improving its geometry, articulation, and overall driving dynamics both on and off the pavement. Based on my experience, the benefits are immediately noticeable and truly transformative.

Enhanced Articulation: Conquering Any Terrain

This is arguably the most significant advantage of a long arm setup. With standard short control arms, as your suspension compresses or extends, the control arm’s angle changes dramatically. This change in angle fights against the natural movement of the axle, limiting how far your wheels can drop or tuck, thus reducing articulation.

Longer control arms, by virtue of their length, maintain much flatter angles throughout the suspension’s travel. This allows your axles to move much more freely and independently, enabling your tires to stay in contact with uneven terrain for longer periods. The result? Superior traction, fewer instances of a tire lifting off the ground, and a vastly improved ability to crawl over obstacles that would leave short arm setups struggling for grip.

Improved Ride Quality: On-Road Comfort, Off-Road Smoothness

One of the most surprising benefits for many XJ owners is the dramatic improvement in ride quality, both on and off the road. The flatter operating angles of the long control arms mean less binding and resistance as the suspension moves. This translates directly into a smoother, less harsh ride.

On the pavement, you’ll notice less bump steer and a more controlled feel over road imperfections. Off-road, the vehicle absorbs bumps and dips more effectively, reducing jarring impacts and providing a more comfortable experience for both driver and passengers. It’s a game-changer for long trail rides or daily driving a lifted XJ.

Reduced Control Arm Angles & Driveline Harmony

When you lift an XJ, especially above 3-4 inches, the factory short control arms become very steep. This extreme angle causes several problems: increased stress on the control arm bushings, a tendency for the suspension to "kick back" over obstacles, and often, issues with driveline vibrations.

Long arm kits inherently correct these steep angles. By relocating the frame-side mounts further back, the arms run much closer to parallel with the ground. This not only reduces stress on components but also significantly improves the suspension’s ability to absorb impacts smoothly, preventing that jarring "kick" that short arm setups often exhibit. Furthermore, by improving the pinion angle, long arm kits often mitigate or even eliminate common driveline vibration issues that plague lifted XJs, especially when paired with a Slip Yoke Eliminator (SYE) and a CV driveshaft.

Increased Stability: Confidence in Every Maneuver

The wider stance and optimized geometry provided by many long arm kits contribute to enhanced stability. Whether you’re navigating off-camber trails, traversing steep inclines, or simply driving at highway speeds, a long arm setup helps keep your XJ more planted and predictable.

This improved stability translates into greater confidence behind the wheel, allowing you to tackle more challenging obstacles with ease and enjoy a more relaxed driving experience on the road. It minimizes body roll and wander, making your XJ feel much more composed and capable.

Durability and Strength: Built to Endure

Let’s face it: off-roading is tough on vehicles. Long arm kits are typically engineered with heavy-duty materials, thicker steel, and robust welds designed to withstand the rigors of aggressive trail use. The larger, stronger control arms and reinforced crossmember add significant structural integrity to your XJ’s front end.

This increased durability means less worry about bending or breaking components when you’re far from civilization. It’s an investment in the longevity and resilience of your off-road machine, allowing you to push harder and venture further with peace of mind.

Key Factors to Consider When Choosing the Best XJ Long Arm Kit

Selecting the "best" XJ long arm kit isn’t a one-size-fits-all decision. It depends heavily on your intended use, budget, and mechanical aptitude. Here are the critical factors to meticulously evaluate before making your choice:

1. Lift Height Compatibility

First and foremost, consider your current or desired lift height. Most long arm kits are designed for specific lift ranges, typically starting around 4.5 inches and going up to 8 inches or more. Installing a long arm kit on a lift that’s too low might lead to clearance issues, while installing one on a lift that’s too high could compromise optimal geometry. Ensure the kit you choose is engineered for your XJ’s specific lift.

2. Material and Construction Quality

The strength and durability of your long arm kit largely depend on the materials used and the quality of construction. Look for:

• Steel Thickness: Thicker steel (e.g., 1/4" or 3/16" wall tubing for control arms) offers superior strength.
• Welds: High-quality, consistent welds are crucial for structural integrity. Poor welds are a red flag.
• Bushings: Are they rebuildable? What material are they (polyurethane, rubber, flex joints)? Flex joints (e.g., Johnny Joints, Currie joints) offer superior articulation and durability but might require more maintenance. Rubber bushings provide a softer ride but less articulation.
• Coatings: Powder coating or other protective finishes are essential to prevent rust and corrosion, especially if you live in a harsh climate.

3. Mounting Points: Weld-On vs. Bolt-On

Long arm kits come in two primary mounting styles for the frame-side components:

• Bolt-on: Easier to install for the average DIYer, requiring less specialized equipment. However, they might not offer the same ultimate rigidity as a properly welded setup.
• Weld-on: Generally considered stronger and more robust, as they become an integral part of your XJ’s unibody. This option requires welding skills and equipment, or professional installation. Based on my experience, weld-on kits, especially when combined with frame stiffeners, provide unparalleled strength for hardcore off-roading.

4. Driveline Angles: Plan for Success

A common mistake is installing a long arm kit without addressing potential driveline issues. With lifts typically requiring long arms, you’ll almost certainly need a Slip Yoke Eliminator (SYE) kit for your transfer case and a CV (constant velocity) driveshaft. The long arm kit’s design should help optimize pinion angle, but final adjustments are often necessary. Neglecting this can lead to severe vibrations and premature U-joint failure.

5. Adjustability: Fine-Tuning Your Ride

The best long arm kits offer a high degree of adjustability. Look for:

• Adjustable Control Arms: These allow you to fine-tune your caster angle (critical for steering stability), pinion angle (to prevent driveline vibrations), and even your wheelbase.
• Adjustable Track Bar: Essential for centering your front axle after a lift.
• Adjustable Sway Bar Links: To accommodate different lift heights and articulation needs.
  Pro Tip from Us: Adjustability means you can dial in your suspension precisely for your specific setup and driving preferences, which is invaluable for optimal performance and comfort.

6. Ease of Installation: DIY or Professional?

Be realistic about your mechanical skills and available tools. A long arm installation is a significant undertaking, often requiring cutting, grinding, and potentially welding. If you’re not comfortable with these tasks, factor in the cost of professional installation. Some kits are designed to be more "user-friendly" for home mechanics, while others are built with the expectation of expert installation.

7. Budget: Quality Over Compromise

Long arm kits are a substantial investment. While it’s tempting to go for the cheapest option, remember the adage: "Buy once, cry once." A low-quality kit can lead to endless headaches, premature wear, and even safety concerns. Set a realistic budget, but prioritize quality and features that align with your intended use. Consider the long-term value and durability.

8. Brand Reputation and Support

Research reputable manufacturers known for their quality, engineering, and customer support. Brands with a long history in the off-road community and positive reviews are generally a safer bet. Good customer support can be invaluable if you encounter installation questions or need replacement parts down the line.

Our Top Picks: The Best XJ Long Arm Kits Reviewed (By Feature Set)

While I can’t name specific product models due to the ever-evolving market and varying availability, I can describe the characteristics and feature sets that define the best XJ long arm kits on the market. These represent the types of kits you should be looking for, each excelling in different areas.

1. The All-Rounder: Balanced Performance for Daily Drivers & Weekend Warriors

• Target User: The XJ owner who drives their Jeep daily but also hits challenging trails on the weekends. They need a kit that performs well in both environments.
• Key Features:
  • Adjustable Upper & Lower Control Arms: Typically made from robust 2" x .250" DOM (Drawn Over Mandrel) tubing or similar heavy-duty steel.
  • High-Quality Flex Joints: Often featuring rebuildable spherical rod ends (like Johnny Joints) at one end and durable rubber or Clevite-style bushings at the other, offering a good balance of articulation and road manners.
  • Beefy Crossmember: Bolt-on design for easier installation, often with integrated transmission mount and skid plate.
  • Compatibility: Designed for 4.5" to 6.5" of lift.
• Pros: Excellent ride quality, significant articulation improvement, relatively straightforward installation (for a long arm kit), good durability for most uses.
• Cons: Might not be as extreme as dedicated competition kits, bolt-on crossmember may offer slightly less ultimate strength than a fully welded one.

2. The Hardcore Crawler: Maximum Articulation and Unmatched Durability

• Target User: The dedicated off-roader or rock crawler who demands the absolute best in strength, articulation, and abuse-taking capability. Daily driving comfort is secondary to trail performance.
• Key Features:
  • Massive Control Arms: Often 2.25" or 2.5" OD thick-wall DOM tubing, built to withstand extreme punishment.
  • Full Flex Joint Design: Utilizes high-end, fully rebuildable spherical rod ends (e.g., Johnny Joints, K-Joins) at both ends of all control arms for maximum bind-free articulation.
  • Weld-On Crossmember & Frame Brackets: Designed to become an integral part of the unibody, providing unparalleled strength and rigidity. Often includes integrated belly pan or extensive skid plating.
  • Extreme Adjustability: Offers fine-tuning for caster, pinion, and wheelbase, allowing for optimal geometry even with very high lifts (6.5" and above).
• Pros: Unrivaled articulation, extreme durability, bomb-proof construction, perfect for severe off-road conditions.
• Cons: Installation is significantly more complex, often requiring welding and fabrication skills. Ride quality on pavement can be firmer due to less compliant joints. Higher price point.

3. The Value Performer: Solid Upgrade Without Breaking the Bank

• Target User: The budget-conscious XJ owner looking for a significant upgrade over short arms without compromising too much on quality or features.
• Key Features:
  • Heavy-Duty Control Arms: Usually 1.75" or 2" OD steel tubing, thicker than stock but perhaps not as massive as hardcore kits.
  • Combination Bushings: Often a mix of rubber bushings for comfort and basic flex joints for articulation, balancing cost and performance.
  • Bolt-On Crossmember: Designed for easier installation, often with basic skid plate features.
  • Good Compatibility: Generally designed for 4.5" to 6" lifts, providing a noticeable improvement over short arms.
• Pros: Excellent value for the money, noticeable improvement in articulation and ride, easier installation compared to weld-on kits, a great entry point into long arm setups.
• Cons: May not offer the same ultimate strength or articulation as higher-end kits, bushings might wear faster than premium flex joints, less adjustability.

Pro Tips from Us: Don’t just look at the price tag. Compare the types of joints used, the wall thickness of the tubing, and the design of the crossmember. Sometimes spending a little more upfront on a better quality kit will save you significant headaches and costs down the road. Also, consider the availability of replacement parts for wear items like bushings and joints.

Installation Insights: What to Expect When Installing Your XJ Long Arm Kit

Installing an XJ long arm kit is a serious project, not a weekend afternoon job for the inexperienced. Based on my experience, it can be challenging but incredibly rewarding. Here’s what you should anticipate:

Complexity and Time Commitment

This isn’t a simple bolt-on affair. A long arm installation typically involves removing significant portions of your old suspension, cutting off factory control arm mounts, drilling new holes, and potentially welding. Depending on your skill level, tools, and the specific kit, expect anywhere from 20-40 hours of labor. This is a multi-day project, so plan accordingly.

Tools Required

You’ll need more than just a basic wrench set. Essential tools often include:

• Jack stands and a robust floor jack: Safety first!
• Impact wrench: For stubborn bolts.
• Grinder with cutting and grinding wheels: For removing old mounts and cleaning surfaces.
• Drill and heavy-duty drill bits: For new mounting holes.
• Torque wrench: Crucial for proper assembly and safety.
• Measuring tape and angle finder: For setting geometry.
• Welder and associated safety gear (if weld-on kit): Or a professional welder.
• Basic hand tools: Wrenches, sockets, pry bars, etc.

Frame Stiffening: A Highly Recommended Companion

Many XJ owners, especially those installing weld-on long arm kits or planning aggressive off-road use, choose to install unibody frame stiffeners simultaneously. The XJ’s unibody, while strong, can flex under extreme stress. Bolting or welding a robust long arm crossmember to a relatively flexible unibody can concentrate forces and potentially lead to cracking. Full-length frame stiffeners reinforce the entire unibody, distributing stress more effectively and creating a much stronger foundation for your new suspension. This is a modification I always recommend considering with a long arm kit.

Driveline Modifications are Essential

As mentioned earlier, a Slip Yoke Eliminator (SYE) and a CV driveshaft are almost always necessary when installing a long arm kit on an XJ, especially with lifts above 3-4 inches. The long arms allow for greater articulation, which exaggerates driveline angles. An SYE and CV shaft are designed to handle these increased angles and prevent vibrations and premature U-joint failure. Don’t skip this crucial step!

Professional Help: When to Call in the Experts

If you lack the necessary tools, skills, or confidence to tackle such a complex installation, don’t hesitate to seek professional help. A reputable off-road shop with experience installing long arm kits can ensure the job is done correctly, safely, and efficiently. While it adds to the cost, the peace of mind and proper functionality are well worth the investment.

Common Mistakes to Avoid:

• Rushing the process: Take your time, double-check measurements, and follow instructions precisely.
• Neglecting alignment: After installation, a professional alignment is absolutely critical to ensure proper steering, tire wear, and handling. Don’t skip it!
• Improper torque: Under-tightened bolts can loosen, over-tightened bolts can strip or break. Always use a torque wrench.
• Ignoring driveline angles: This will lead to vibrations and component failure. Address it proactively.

Living with a Long Arm XJ: Maintenance and Beyond

Once your XJ is equipped with its new long arm suspension, the adventure truly begins! However, to ensure longevity and continued performance, a proactive approach to maintenance is key.

Regular Inspections

Make it a habit to regularly inspect all components of your long arm kit. This includes:

• Control arms: Check for any bends, cracks, or signs of impact damage.
• Bushings and Joints: Look for wear, cracking, or excessive play. Worn joints are a primary source of clunks and poor handling.
• Mounting Hardware: Ensure all bolts are properly torqued and haven’t loosened. Pay close attention to the crossmember and frame brackets.
• Driveshaft and U-joints: Check for any signs of wear, especially after strenuous off-road trips.

Greasing and Lubrication

Many long arm kits utilize greasable flex joints or bushings. Regular lubrication according to the manufacturer’s recommendations is vital to prevent wear, corrosion, and squeaks. Depending on your driving conditions, this could be every oil change or more frequently after heavy mud or water crossings.

Alignment Checks

Even after the initial alignment, it’s a good idea to have your XJ’s alignment checked periodically, especially after hard off-roading. Impacts can knock things out of spec, leading to premature tire wear and compromised handling.

Tire Considerations

With the increased articulation and potential for larger tire sizes, ensure your tires have adequate clearance throughout the full range of suspension travel. This might require fender trimming, bump stop extensions, or even flat fenders to prevent rubbing. Proper bump stop setup is crucial to protect your shocks and prevent tires from contacting the body.

Conclusion: Elevate Your XJ Experience with the Right Long Arm Kit

Choosing and installing the best XJ long arm kit is a significant investment in your Jeep’s capability and your off-road adventures. It’s a modification that fundamentally transforms how your XJ performs, offering unparalleled articulation, a dramatically improved ride, and the strength to tackle nearly any trail you dare to conquer.

By understanding the mechanics, considering the critical factors, and anticipating the installation process, you’re now equipped to make an informed decision. Whether you’re a weekend warrior or a hardcore rock crawler, there’s a long arm kit designed to unleash your XJ’s true potential. Do your research, choose wisely, and get ready to experience a whole new level of performance from your beloved Jeep Cherokee.

What’s your experience been with XJ long arm kits? Share your thoughts, tips, and favorite brands in the comments below! We’d love to hear from you.