Since this is such a new bumper, I wanted to put my experiences (and problems) with it out there for everyone. This install was on a completely stock '92 XJ. I'm not going to do a comprehensive step-by-step how-to. This is just an overview of some of the issues I had with the install.
The biggest issue I had was involving the passenger side frame rail tie-in bracket. Smittybilt includes a nut plate to go on the inside of the frame rail, but on mine I had a problem:
Two issues here: 1) The c-channel that houses the sway bar nuts comes up half way through the hole so the bolt won't go through:
And 2) The nut plate won't sit flush against the frame rail.
After much talking with a guy at Smittybilt, him talking to the engineers, me sending everyone photos, etc. they told me to drill out the c-channel and bolt the nut plate down anyway. I don't think so. I'd rather not have my bolt snap in half because the nut was only contacting 1/2 the surface it's supposed to. Solution:
Using some Harbor Freight metal files, I filed down the c-channel in both sides of the frame rail until I could get a bolt through. I then went down to my local hardware shop and got a 3.5” grade 8 bolt and nut in a size that matched the others in the kit (I forget exactly what size it was). This allowed me to put the bolt all the way through the frame to the other side. I was worried about pinching the frame inward, but with the c-channel in there, there should be plenty of support.
Now the bolt is sitting where the nut plate is supposed to go, so I just cut that part of the plate off where the red line is (sorry I didn't grab a pic of the actual plate after cutting. I started getting impatient and not taking time for pictures):
The 1/2” (I think) bolt that Smittybilt supplies for the last hole in the bracket didn't go through the hole, so I had to drill it out:
Now the passenger side tie-in bracket should bolt up. The driver side bracket was much easier. I just had to drill out the last hole in the bracket for the large bolt and make sure everything lined up. One tip I have is to install the top steering box bolt first, then push the steering box into place for the bottom two. I did have one issue on the driver side:
This was pretty much solved by loosening the steering pump bolts, putting something in that hole, and prying up while tightening the steering pump bolts. Then I was able to (forcefully) get the last bolt in.
Apparently Smittybilt test-fit this bumper on a number of Cherokees from various years. I don't know how they possibly got this kit to work out of the box on those rigs, because as far as I know (correct me if I'm wrong), all XJs have that sway bar bracket in the frame. Of course this bumper also requires cutting the fenders on 1st-gen models, which I did. I still have some finishing work to do like trimming the fender liners and such:
But here's the installed bumper:
All-in-all I'm happy with the bumper because despite the ridiculous amount of work I needed to do for it to bolt up, I only paid $400+tax and it gives me a way to mount my winch. If it were as expensive as some of the other bumpers out there I would have been far more upset about the fitment issues.
I'd love to hear other people's experiences with this bumper, whether it bolted right up or if you had issues similar to mine. Apparently Smittybilt has sold over 100 of these and I was the first to call about any issues. I will say that Eric at ProComp (the Smittybilt rep was on break) was a pleasure to work with and a huge Cherokee nut.
-Andrew
P.S.: The sketchy looking jack stand on the tire is just holding the engine in place while the tranny is out.
The biggest issue I had was involving the passenger side frame rail tie-in bracket. Smittybilt includes a nut plate to go on the inside of the frame rail, but on mine I had a problem:
Two issues here: 1) The c-channel that houses the sway bar nuts comes up half way through the hole so the bolt won't go through:
And 2) The nut plate won't sit flush against the frame rail.
After much talking with a guy at Smittybilt, him talking to the engineers, me sending everyone photos, etc. they told me to drill out the c-channel and bolt the nut plate down anyway. I don't think so. I'd rather not have my bolt snap in half because the nut was only contacting 1/2 the surface it's supposed to. Solution:
Using some Harbor Freight metal files, I filed down the c-channel in both sides of the frame rail until I could get a bolt through. I then went down to my local hardware shop and got a 3.5” grade 8 bolt and nut in a size that matched the others in the kit (I forget exactly what size it was). This allowed me to put the bolt all the way through the frame to the other side. I was worried about pinching the frame inward, but with the c-channel in there, there should be plenty of support.
Now the bolt is sitting where the nut plate is supposed to go, so I just cut that part of the plate off where the red line is (sorry I didn't grab a pic of the actual plate after cutting. I started getting impatient and not taking time for pictures):
The 1/2” (I think) bolt that Smittybilt supplies for the last hole in the bracket didn't go through the hole, so I had to drill it out:
Now the passenger side tie-in bracket should bolt up. The driver side bracket was much easier. I just had to drill out the last hole in the bracket for the large bolt and make sure everything lined up. One tip I have is to install the top steering box bolt first, then push the steering box into place for the bottom two. I did have one issue on the driver side:
This was pretty much solved by loosening the steering pump bolts, putting something in that hole, and prying up while tightening the steering pump bolts. Then I was able to (forcefully) get the last bolt in.
Apparently Smittybilt test-fit this bumper on a number of Cherokees from various years. I don't know how they possibly got this kit to work out of the box on those rigs, because as far as I know (correct me if I'm wrong), all XJs have that sway bar bracket in the frame. Of course this bumper also requires cutting the fenders on 1st-gen models, which I did. I still have some finishing work to do like trimming the fender liners and such:
But here's the installed bumper:
All-in-all I'm happy with the bumper because despite the ridiculous amount of work I needed to do for it to bolt up, I only paid $400+tax and it gives me a way to mount my winch. If it were as expensive as some of the other bumpers out there I would have been far more upset about the fitment issues.
I'd love to hear other people's experiences with this bumper, whether it bolted right up or if you had issues similar to mine. Apparently Smittybilt has sold over 100 of these and I was the first to call about any issues. I will say that Eric at ProComp (the Smittybilt rep was on break) was a pleasure to work with and a huge Cherokee nut.
-Andrew
P.S.: The sketchy looking jack stand on the tire is just holding the engine in place while the tranny is out.
