Installing Bushwacker fender flares on an XJ Cherokee gives it a wider stance and more tire clearance. If you own a Jeep Cherokee XJ, you know the stock wheel wells are tight. Adding larger tires for off-roading or a tougher look requires a solution. The Jeep Cherokee XJ Bushwacker fender flares are a popular upgrade that solves this problem cleanly.
These flares are made from durable plastic. They bolt over your existing fenders. They add about two inches of width on each side. This lets you run 31-inch or even 33-inch tires without rubbing. The installation is a weekend project for most DIYers.
In this guide, we cover everything. You will learn about the benefits, the installation steps, and some common mistakes to avoid. Let’s get started.
Why Choose Bushwacker Fender Flares For Your XJ
Bushwacker has been making fender flares for decades. Their products are known for toughness and a factory-like fit. For the XJ Cherokee, they offer a few key advantages over other brands.
More Tire Clearance Without A Lift
Stock XJ fenders are restrictive. Even with a small lift, 31-inch tires can rub on the inner fender or the lower control arms. Bushwacker flares push the fender opening outward. This gives you the clearance needed for bigger tires. You can often fit 31s with just a budget boost lift.
Durable Material That Handles Trails
The flares are made from a UV-resistant polymer. They won’t rust or crack easily. If you scrape a rock or a tree branch, the flare flexes instead of breaking. This is important for off-road use. The material is also paintable if you want to match your Jeep’s color.
Improved Look With A Wider Stance
The wider stance is not just functional. It gives your XJ a more aggressive, planted appearance. The flares cover the gap between the tire and the fender edge. This makes the Jeep look lower and wider. Many owners say it completes the off-road look.
Jeep Cherokee Xj Bushwacker Fender Flares
Now let’s talk about the specific product. The Bushwacker pocket-style flares are the most common choice for the XJ. They have a rugged, textured finish. They come as a set of four flares: two front and two rear. Each flare includes the necessary hardware and a template for drilling.
The flares are designed to fit 1984 to 2001 Jeep Cherokee XJ models. They work with both two-door and four-door versions. The installation requires cutting the stock fender lip. This is a permanent modification, so measure twice before cutting.
What’s Included In The Box
- Four fender flares (front left, front right, rear left, rear right)
- Mounting hardware (screws, clips, and nuts)
- Drilling template for each flare
- Installation instructions
- Edge trim to protect the cut metal
Tools You Will Need
- Angle grinder or air saw for cutting metal
- Drill with various drill bits
- Screwdriver (Phillips and flathead)
- Measuring tape
- Marker or chalk
- Safety glasses and gloves
- Rust inhibitor or paint for exposed metal
Step-By-Step Installation Guide
Installing Bushwacker fender flares is a straightforward process. But it requires patience and careful work. Follow these steps for a clean installation.
Step 1: Prepare Your XJ
Park your Jeep on a level surface. Remove the wheels for better access. This is not strictly necessary, but it makes cutting and drilling much easier. Clean the fender areas thoroughly. Dirt and grease will mess up your template alignment.
Step 2: Remove The Stock Fender Flares
Your XJ likely has small plastic trim pieces on the fender edges. Remove these by prying them off. Some are held by clips, others by screws. Set them aside. You won’t reuse them.
Step 3: Mark The Cut Line
Each Bushwacker flare comes with a paper template. Tape the template to the fender. Align it carefully using the wheel well as a reference. Use a marker to trace the cut line. Double-check the alignment on both sides. The flares should be symmetrical.
Step 4: Cut The Fender Lip
This is the scariest part. Use an angle grinder with a cutting wheel. Cut along the marked line. Take your time. Cut in small sections. Do not try to cut the entire line in one pass. The metal is thin, so it cuts easily. Wear safety glasses to protect your eyes from sparks.
After cutting, smooth the edges with a file or sandpaper. Apply a rust inhibitor or primer to the exposed metal. This prevents rust from forming later.
Step 5: Test Fit The Flares
Hold each flare in place. Check that it covers the cut edge properly. The flare should sit flush against the fender. If it does not, you may need to trim a little more metal. Do not force the flare into place.
Step 6: Drill Mounting Holes
Use the template again to mark the hole locations. Drill small pilot holes first. Then enlarge them to the size specified in the instructions. Be careful not to drill into any wiring or brake lines behind the fender.
Step 7: Install The Edge Trim
The kit includes a rubber edge trim. Slide this over the cut metal edge. This protects the flare from rubbing against the metal. It also gives a finished look. Make sure the trim is seated all the way.
Step 8: Mount The Flares
Start with the front flares. Align them with the drilled holes. Insert the screws and clips. Tighten them by hand first. Then use a screwdriver to snug them up. Do not overtighten. The plastic can crack if you apply too much force.
Repeat for the rear flares. Check that all flares are evenly spaced. The gaps between the flare and the body should be consistent.
Step 9: Reinstall The Wheels And Test
Put the wheels back on. Lower the Jeep to the ground. Turn the steering wheel fully left and right. Check for any rubbing. If the tires hit the flares, you may need to adjust the flare position or trim more metal.
Common Mistakes To Avoid
Even experienced DIYers make errors. Here are the most common ones.
Cutting Too Much Metal
It is better to cut less and then trim more. If you cut too much, you cannot undo it. The flare might not cover the gap. Measure twice, cut once.
Not Protecting The Cut Edge
Rust is a big problem on XJs. The cut metal is exposed to moisture. Always apply primer or paint to the cut edge. Some people use a rust converter. Do not skip this step.
Drilling Holes In The Wrong Place
Use the template. Do not guess. Drilling holes too high or too low will cause the flare to sit crooked. Check alignment before drilling.
Overtightening The Screws
The plastic flares are strong but not indestructible. Overtightening can crack the material or strip the threads. Snug is enough.
Benefits Beyond Tire Clearance
The flares offer more than just room for bigger tires. They also protect your paint. When you drive on gravel or mud, rocks can chip the fender edges. The flares act as a shield.
They also reduce the amount of mud and water thrown up onto the body. This keeps your Jeep cleaner on the trail. Some owners report less dirt buildup on the side windows.
Are Bushwacker Flares Street Legal
In most states, fender flares must cover the tire tread. Bushwacker flares are designed to meet this requirement. However, laws vary. Check your local regulations. Some areas require the flares to extend to the outer edge of the tire. If your tires stick out past the flares, you might get a ticket.
Painting Vs. Leaving Them Black
The flares come in a textured black finish. Many people leave them as is. This gives a rugged, off-road look. Others paint them to match the body color. If you paint, use a flexible primer and paint designed for plastic. Regular paint will crack over time.
Maintenance Tips For Long Life
Bushwacker flares require minimal upkeep. Wash them with soap and water. Avoid harsh chemicals. If the flares get scratched, you can use a heat gun to blend the plastic. Do not use abrasive cleaners.
Check the mounting screws occasionally. They can loosen over time due to vibration. Tighten them if needed. Replace any missing screws promptly.
Frequently Asked Questions
Will Bushwacker Fender Flares Fit A 1999 Jeep Cherokee Xj
Yes. The flares fit all XJ models from 1984 to 2001. The mounting points are the same. Just make sure you buy the correct set for your year. The pocket-style flares are universal for all XJs.
Can I Install These Flares Without Cutting The Fender
No. The flares are designed to replace the stock fender lip. You must cut the metal to create clearance. Without cutting, the flares will not fit properly. They will stick out too far and look odd.
How Much Wider Do Bushwacker Flares Make The Xj
Each flare adds about 2 inches of width. This means the total track width increases by 4 inches. This gives you room for tires up to 33 inches with the right lift.
Do I Need A Lift To Use These Flares
Not necessarily. You can fit 31-inch tires with no lift if you use these flares. But for 33-inch tires, you will need at least a 3-inch lift. The flares alone do not lift the Jeep. They just give more clearance in the wheel well.
Are Bushwacker Flares Better Than Other Brands
Bushwacker is a trusted name. Their flares are thicker and more durable than many cheaper brands. The fitment is usually better. However, they are more expensive. If you are on a budget, other brands like Rugged Ridge or Smittybilt offer similar products at a lower price.
Final Thoughts On The Upgrade
Adding Bushwacker fender flares to your Jeep Cherokee XJ is a smart move. It improves both looks and function. The installation is doable in a weekend with basic tools. The result is a more capable off-road machine that turns heads.
Take your time with the cutting and drilling. Rushing leads to mistakes. If you are unsure, ask a friend for help. The payoff is worth the effort. Your XJ will look tougher and handle bigger tires with ease.
Remember to check your local laws about fender coverage. And always protect the cut metal from rust. With proper care, your Bushwacker flares will last for years.
Now go ahead and give your XJ the stance it deserves. The trail is waiting.