Bushwacker fender flares give a Jeep Cherokee XJ a wider stance and room for bigger tires without rubbing against the body. If you own a Jeep Cherokee XJ, you know the struggle of fitting larger tires under the stock fenders. The Bushwacker fender flares Jeep Cherokee XJ upgrade is the most popular solution for off-road enthusiasts who want to clear 31-inch, 33-inch, or even 35-inch tires. This guide covers everything from installation to maintenance, so you can get the most out of your XJ’s new look and performance.
These flares are not just about looks. They protect your paint from rocks and mud, and they give your Jeep a more aggressive appearance. Whether you are a weekend warrior or a daily driver, this article will help you choose, install, and care for your Bushwacker flares.
Why Choose Bushwacker Fender Flares For Your XJ
Bushwacker is a trusted name in off-road accessories. Their fender flares are made from durable materials that can handle rough trails. The Bushwacker fender flares Jeep Cherokee XJ kit is designed specifically for the XJ body style, so you get a perfect fit every time.
Stock fenders limit your tire size to about 29 inches. With Bushwacker flares, you can run up to 33-inch tires with minimal lift. Some owners even fit 35s with a 4-inch lift and these flares. The extra clearance prevents rubbing during articulation, which is critical for off-road driving.
Another reason to choose Bushwacker is the easy installation. Most kits come with all necessary hardware and detailed instructions. You do not need to be a professional mechanic to install them. A weekend afternoon is enough to get the job done.
Bushwacker Fender Flares Jeep Cherokee Xj
The Bushwacker fender flares Jeep Cherokee Xj kit includes four flares: two front and two rear. They are made from ABS plastic, which is lightweight and impact-resistant. The material does not rust or corrode, making it ideal for wet and muddy conditions.
These flares come in two main styles: pocket-style and smooth. Pocket-style flares have exposed bolts that give a rugged, utilitarian look. Smooth flares have a cleaner appearance with hidden fasteners. Both styles offer the same tire clearance, so your choice depends on personal preference.
Bushwacker also offers flat-top flares for the XJ. These have a flatter top surface compared to the rounded stock shape. Flat-top flares are popular for a more modern, boxy look. They also provide slightly more clearance at the top of the wheel well.
Key Features Of Bushwacker Flares
- Durable ABS plastic construction
- UV-resistant coating to prevent fading
- Provides up to 2 inches of additional tire clearance
- Includes stainless steel hardware for rust resistance
- Comes with a limited lifetime warranty
- Easy to install with basic hand tools
- Fits both 2-door and 4-door XJ models
The flares are pre-drilled for the mounting holes, so you do not need to measure anything. They also include a foam gasket that seals against the body to prevent dirt and water from getting behind the flare.
Preparing For Installation
Before you start, gather all necessary tools and materials. You will need a drill, a screwdriver, a socket set, and a marker. Some installations require trimming the stock fenders, so a angle grinder or jigsaw may be needed.
Read the instructions that come with your kit. Bushwacker provides detailed steps for each model year. The process is similar for all XJs, but there are slight differences for pre-1997 and 1997-2001 models.
Clean the area around the fenders thoroughly. Remove any mud, grease, or old adhesive. This ensures the foam gasket adheres properly and prevents rust. If your XJ has rust around the fenders, treat it before installing the flares.
Tools You Will Need
- Drill with 1/8-inch and 1/4-inch bits
- Phillips and flathead screwdrivers
- 10mm and 13mm sockets
- Marker or pencil
- Angle grinder or jigsaw (if trimming is needed)
- Rubbing alcohol or degreaser
- Masking tape
Make sure you have a helper for the installation. Holding the flares in place while drilling can be tricky alone. A second person makes the job faster and more accurate.
Step-By-Step Installation Guide
Follow these steps to install your Bushwacker fender flares Jeep Cherokee XJ kit. Take your time and double-check each step. Rushing can lead to misalignment or damage to the flares.
Step 1: Remove The Stock Flares
Start by removing the factory fender flares. On most XJs, these are held on by screws and plastic clips. Use a screwdriver to remove the screws along the top edge. Then gently pull the flare away from the body. Some flares have adhesive tape, so you may need to apply some force.
Once removed, clean the exposed area. Remove any leftover adhesive or dirt. This is a good time to inspect the fender for rust or damage. Repair any issues before proceeding.
Step 2: Trim The Fenders (If Required)
Depending on your tire size, you may need to trim the inner fender lip. Bushwacker flares cover the cut area, so you do not need to worry about aesthetics. Use a angle grinder or jigsaw to cut along the marked line. Wear safety glasses and gloves during this step.
For 31-inch tires, trimming is usually not needed. For 33-inch or larger, you will need to cut the fender lip. The instructions in your kit will show the exact cutting line. Measure twice and cut once to avoid mistakes.
Step 3: Test Fit The Flares
Place the new flare over the fender without removing the protective film. Align the mounting holes with the body. Check the fitment around the wheel well. The flare should sit flush against the body. If it does not, adjust the position until it fits properly.
Mark the mounting hole locations with a marker. Remove the flare and drill pilot holes at the marked spots. Use a 1/8-inch bit for plastic and a 1/4-inch bit for metal. Be careful not to drill into any wiring or brake lines behind the fender.
Step 4: Attach The Flares
Apply the foam gasket to the back of the flare. Peel off the backing and press it firmly into place. Then position the flare over the fender and insert the screws. Tighten them by hand first, then use a socket to secure them. Do not overtighten, as this can crack the plastic.
Repeat the process for all four flares. Work in a cross pattern to ensure even pressure. Check the alignment as you go. Adjust if necessary before fully tightening all screws.
Step 5: Final Checks
Once all flares are installed, check the fitment again. Make sure there are no gaps between the flare and the body. Test the wheel clearance by turning the steering fully left and right. Also check for clearance during suspension articulation.
If you notice any rubbing, you may need to trim more from the fender or adjust the flare position. Most installations require no further adjustments.
Tire And Lift Recommendations
Bushwacker flares work best with specific tire and lift combinations. Here are some popular setups for the XJ:
- 31-inch tires with a 2-inch lift: No trimming needed, flares provide extra clearance
- 33-inch tires with a 3-4 inch lift: Requires trimming of the fender lip
- 35-inch tires with a 4-6 inch lift: Significant trimming and bump stop extensions needed
The flares give you about 2 inches of additional width on each side. This means your tires will stick out slightly beyond the body. Check local laws regarding tire coverage, as some states require the tire to be fully covered by the fender.
For daily driving, a 2-inch lift with 31-inch tires is a great balance. You get improved off-road capability without sacrificing too much on-road comfort. For serious off-roading, go with 33-inch tires and a 3-inch lift.
Maintenance And Care
Bushwacker flares are low-maintenance, but they do require some care to keep them looking good. Wash them regularly with soap and water to remove mud and dirt. Avoid using harsh chemicals or abrasive cleaners.
Over time, the UV coating may fade, especially if you park in direct sunlight. You can apply a plastic trim restorer to bring back the color. Some owners paint the flares to match the body color for a custom look.
Check the mounting screws periodically. They can loosen over time due to vibrations. Tighten them if needed. Also inspect the foam gasket for wear. Replace it if it starts to peel or crack.
Common Issues And Solutions
- Flare not fitting flush: Check for debris behind the flare or bent mounting tabs
- Screws rusting: Use stainless steel hardware from the kit or replace with aftermarket bolts
- Flare cracking: Avoid overtightening screws; use rubber washers to reduce stress
- Paint fading: Apply a UV protectant or repaint with flexible bumper paint
If you notice any cracks or damage, you can repair them with plastic epoxy. For severe damage, replacement flares are available from Bushwacker or aftermarket suppliers.
Cost And Where To Buy
The Bushwacker fender flares Jeep Cherokee XJ kit costs between $300 and $500, depending on the style and retailer. Pocket-style flares are usually cheaper than smooth ones. Flat-top flares may cost a bit more due to their design.
You can buy them from online retailers like Quadratec, ExtremeTerrain, or Amazon. Local off-road shops may also carry them. Check for sales or bundle deals that include installation kits or hardware.
Shipping costs can vary based on your location. Some retailers offer free shipping for orders over a certain amount. Compare prices before buying to get the best deal.
Alternatives To Bushwacker Flares
If Bushwacker flares are not for you, there are other options. Rusty’s Off-Road offers similar flares made from steel. These are heavier but more durable. Smittybilt also makes flares for the XJ, though they are less common.
Another option is to cut the stock fenders and use a fender trim kit. This is cheaper but requires more work. You can also install tube fenders for maximum clearance, though they are more expensive.
Bushwacker remains the most popular choice because of the balance between cost, ease of installation, and performance. They are a proven upgrade for the XJ community.
Frequently Asked Questions
Do Bushwacker fender flares fit all Jeep Cherokee XJ years?
Yes, they fit both 2-door and 4-door models from 1984 to 2001. Some kits may require slight modifications for pre-1997 models due to different body lines.
Can I install Bushwacker flares without cutting the fenders?
Yes, if you are running stock or 31-inch tires. For larger tires, trimming is required to prevent rubbing.
How much tire clearance do Bushwacker flares add?
They add about 2 inches of clearance at the top and sides of the wheel well. This allows for up to 33-inch tires with a moderate lift.
Are Bushwacker flares legal for road use?
They are legal in most states, but check local laws. Some states require tires to be fully covered by the fender. If your tires stick out too far, you may need mud flaps.
Can I paint Bushwacker flares to match my Jeep?
Yes, you can paint them with flexible bumper paint. Clean and prime the surface first for best adhesion.
Final Thoughts
Installing Bushwacker fender flares on your Jeep Cherokee XJ is a smart upgrade. It gives you the clearance you need for larger tires, protects your paint, and improves the look of your rig. The installation is straightforward, and the results are immediate.
Whether you choose pocket-style or smooth flares, you are getting a quality product that will last for years. Take your time during installation, maintain them properly, and you will enjoy your XJ even more on and off the trail.
If you have any questions about fitment or installation, ask in the XJ forums or consult a local off-road shop. The XJ community is full of helpful people who have done this upgrade themselves. Now get out there and make your Cherokee look and perform its best.