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Frame Crack? and options

Wraith40k

NAXJA Forum User
NAXJA Member
Location
Hillsboro Oregon
Hello!

My 2001 XJ sport steering started being unstable at freeway speeds, particularly while turning right about a month ago. It hadn't been off road in 7+ months, so I thought it was me and took it in for an alignment to Iron Rigs 4x4 here in Oregon.

They said the unibody frame is cracked and provided the attached video. (The bolt in the video they loosened for testing).
Frame Crack on youtube
After getting it home, I started doing research and things they said didn't add up - like the crack is on the passenger side - but the video is of the drivers side. And that looks like the steering box spacer that is cracked...

Questions:
A) Is that the frame that is cracked? (i looked as best I could and felt around the area and couldn't find any other cracks or problems)
B) if the frame is cracked - would the combination of fish plate welding + Frame stiffeners + full steering box brace be the right path to keep this XJ viable?

I plan on getting a second opinion, so any suggestions for the hillsboro (or even portland) area of a good shop to both review and potentially repair (and install the frame stiffeners etc.) would be appreciated.

Thank you!
 
I looked at the video. I'd take off the gear box. I'd look at the spacer and both sides of the frame. It looks like your spacer is the stock aluminum one. They do crack. Yes, the one on my 2000 XJ was cracked. Many make steel upgraded spacers. Still you actual frame might be cracked. So, take off the gear box and look. One of my '98 XJs had a cracked frame. The outside or wheel well side of the frame. I had a plate welded on. I was going through 'Death Wobble', till I figured that out.
Other fixes are frame stiffeners. Many places make them. Also, M&T makes inside stiffeners for the front with the spacers. Stinky Fabs make the same for the driver side. I do have the M&T on my 2000. I do have Stinky Fab stuff on my 2000. I really like SF stuff.
Also, the area gets stress from the Trackbar. Some make trackbar braces. I use Stinky Fabs on the 2000. There are other makers. And some members here have made their own. Most of the makers Trackbar braces are for their trackbar set up.
So, yes, you can repair the area, and if done correctly, it will be better than new. Also, consider a steering box brace. I like Ironmans. I do have Bad Dad Fabs on my 2000. That is also a Hidden Winch Bumper. Also, check Boostworks.
 
I don't see a crack. The piece that is moving between the sway bar bushing and uniframe is not stock. Is that piece what they are calling the crack? Looks like someone added that to beef up the area. Maybe there is a crack under there. That would make sense why they added it. Also are the steering box bolts loose? No way the whole box should move like that. I'd be curious what it looks like if the box and sway bar bushing bolts are all tight. I bet it doesn't move.

What size tires are you running?
 
Thank you both for the help! They didn't remove anything (other than loosening the sway bar) to come up with their diagnosis, so definitely a deeper look is in order.
I was looking at the iron rock frame stiffeners (which others should I consider?) and either the ironman or the bootswork steering brace - prices seem similar, any pros/cons between them?

I have a rubicon express 3.5" lift, drop down brackets for the sway bar, and upgraded track bars, pitman arm, tie rods etc. (trying to make this jeep outlast me :) )
 
Yea pretty sure your steering box bolts are loose, especially the one on the left. From the video, it looks like the box is moving relative to the frame. If the frame was cracked, the box and frame would be moving together. And you can see less of the bolt on the left, unless someone used different length bolts. Did the shop try to sell you any solutions here?

I would put a socket on all 3 steering box bolts yourself before doing anything else. At least rule that out.
 
the shop basically charged me for $200 for what seems like 5-10 minutes of work and an 11 second video…

will tighten everything up tomorrow to check, and then order a steering brace anyways
 
When you are ready to try aligning it again, I recommend taking your XJ to Trackside Motorsports in downtown Portland. Their prices are very reasonable, and they know what they are doing.
 
Do the frame stiffeners, and a upgraded spacer. You'll need it eventually. I have them, and a cross over stiffener that no one makes anymore, a winch bumper, rock rails, and roll cage, the beast doesn't bend much. I can do 80 easily on 35's with upgraded steering.
 

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only running 32’s (265 70r17), and have been carrying a portable winch when going out.
as a novice I really haven’t done 10% of what the jeep is capable of yet, and better people have said I need to get underbody armor before starting to do the more fun things…

so now frame stiffening, steering brace, and armor :)
 
Also, look at Ruff Stuffs steering box brace. Definitely get a steel gear box spacer or a weld in spacer. I really like my frame stiffeners. Still, depends on what level of Offroading or towing. Mine was preventive. Death Wobble is not fun. Many other factors can cause DW.
 
When you are ready to try aligning it again, I recommend taking your XJ to Trackside Motorsports in downtown Portland. Their prices are very reasonable, and they know what they are doing.
Will do! Thank you for the recommendation. Know of any reliable shops that could handle welding the frame stiffeners/braces in the PDX/Hillsboro area?
 
Based on the above I am going to put in the frame stiffeners and steering brace. Even if tightening fixes the problem, I want to bulletproof it as much as possible. Likely will never do anything crazy with this XJ (easy to mid offroading, ice/snow work for getting to the mountain to snowboard etc.)

Stiffeners- Which one?
Hooligans are 'wrap around' at $900 for a full set: https://www.hooliganoffroad.com/collections/xj
Iron Rock: $600 full set: https://www.ironrockoffroad.com/product/xj-unibody-frame-stiffeners-full-set.html
T&M: $300-450 https://www.t-mfab.com/store-3/?model_number=XJUSCK
RuffStuff: $525 full set: https://www.ruffstuffspecialties.com/R2613.html - seems solid - but reviews state the holes are less well matched than the Iron Rock or Hooligans
CavFab: $660 full set: https://cavfab.com/products/frame-stiffener-front-xj - seems standard as well, no reviews I could find.

Stinky Fab (mentioned above) - I wasn't able to find any unibody stiffeners but they have several other crossmembers/reinforcements that will be interesting later
Steering box brace
Boostwerks Engineering:
$348.95 https://www.boostwerksengineering.com/The-Ultimate-XJ-Steering-Brace_p_8.html 3/16" thick
Ironman 4x4 Fab: $383.50 (with spacer) https://ironman4x4fab.com/products/xj-steering-box-brace?variant=29783247323224 1/4" thick
T&M :
$85-180: https://www.t-mfab.com/store-3/?model_number=4761900 separate pieces - probably leaning towards boostwerks for a single piece/crossbar to also strengthen the unibody

Should the answer be Hooligans and boostwerks? Would that be overkill? Is there a downside to overkill (besides price)?
 
Will do! Thank you for the recommendation. Know of any reliable shops that could handle welding the frame stiffeners/braces in the PDX/Hillsboro area?

I don't know any places in Hillsboro. I only know Jeep West (Estacada) or Bones Customs (Oregon City). Jeep West is pretty famous in the Portland area. Bones is less known, but they do many custom Jeep builds, and their shop is nice.

Unibody stiffener installation is expensive work, so you should decide whether you really need it. I think most people can get by with a high quality steering box brace, a track bar mounting bracket brace, beefing up the front bumper mounting to the body, and installing a steel steering box spacer. And you need all these things regardless of whether you do stiffeners.
 
You're also missing Kings offroad for stiffeners.
Steering box spacer, barnes 4wd is the cheapest and comes with bolts. Ruffstuff spacer covers more area.

I have the Barnes on my 91 and 88. I think there is an Ironman4x4 on my 99 but that was before cvid and prices went through the roof on everything.
 
Based on the above I am going to put in the frame stiffeners and steering brace. Even if tightening fixes the problem, I want to bulletproof it as much as possible. Likely will never do anything crazy with this XJ (easy to mid offroading, ice/snow work for getting to the mountain to snowboard etc.)

Stiffeners- Which one?
Hooligans are 'wrap around' at $900 for a full set: https://www.hooliganoffroad.com/collections/xj
Iron Rock: $600 full set: https://www.ironrockoffroad.com/product/xj-unibody-frame-stiffeners-full-set.html
T&M: $300-450 https://www.t-mfab.com/store-3/?model_number=XJUSCK
RuffStuff: $525 full set: https://www.ruffstuffspecialties.com/R2613.html - seems solid - but reviews state the holes are less well matched than the Iron Rock or Hooligans
CavFab: $660 full set: https://cavfab.com/products/frame-stiffener-front-xj - seems standard as well, no reviews I could find.

Stinky Fab (mentioned above) - I wasn't able to find any unibody stiffeners but they have several other crossmembers/reinforcements that will be interesting later
Steering box brace
Boostwerks Engineering:
$348.95 https://www.boostwerksengineering.com/The-Ultimate-XJ-Steering-Brace_p_8.html 3/16" thick
Ironman 4x4 Fab: $383.50 (with spacer) https://ironman4x4fab.com/products/xj-steering-box-brace?variant=29783247323224 1/4" thick
T&M :
$85-180: https://www.t-mfab.com/store-3/?model_number=4761900 separate pieces - probably leaning towards boostwerks for a single piece/crossbar to also strengthen the unibody

Should the answer be Hooligans and boostwerks? Would that be overkill? Is there a downside to overkill (besides price)?
I have Hooligans, all the stiffeners, the crossmember, and front installed. I like them, they are a small shop, and local in CO.
 
I got the hooligans mid frame stiffeners. The wrap around design I think is the best, very very sturdy. Before I bought them I made a list of the near dozen or so types offered, the hooligans were among the thickest gage of them, and the wrap around design is only offered by them, i.e. it is U shaped, covers three sides of the frame.


Now one thing i had was the track bar mount on my frame behind the steering gear, it once was ever so slightly loose, made a loud pop when i turned the steering, tightened the bolts and bingo, no more noise

You want to do frequent retorque of suspension and steering bolts when off roading, specially when usi g high lift and huge tires.

If wheeling you NEED a steel steering box mount plate, and have it attached thru the frame to another steel plate on outside of that frame as a minimum

also recommend a steering box brace

I got one like this...

There is another type like this....

Also consider front frame stiffeners. I may do that soon, it will also give me a better bumper mount, important as I got a winch on the bumper.

oh and on the bolts again, on the lower track bar bolt, it can start to shift, ovalling the hole it is. that is bad. spray paint a shot of a contrasting color over it so if the bolt head does shift, you can instantly see the paint marks indicating you got movement, tighten that bolt tight, recheck after each wheeling trip!!
 
after the frame stiffeners are on, before rebolting everything, what underbody coating would be recommended? Currently have very minimal rust (i am lucky!) and want to keep it that way
 
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