Rusty's XJ Cherokee 4.5" Long Travel Kit


  • Brand: Rusty's Off Road Products
  • Availability: In Stock
  • Part Number: RK-405LT-XJ-RX1-LT10-UB2

The system starts with your choice of radius-arm, 4 link, 3 link, or competition 4 link  long travel system to customize the kit to match your desired use! (Need help to determine the best setup for your use? Click here to see our XJ Long Travel Control Arm Options Guide) Each choice will include our adjustable forged flex joints on both the lower and upper control arms that are rebuildable on the radius arm, 4 link and 3 link options to provide maximum articulation. The competition 4 link will use an adjustable 1-1/4" heim joints to better serve a competition built vehicle. The arms all utilize Clevite factory rubber control arm bushings at the axle end to ensure that no noise or vibrations are transmitted through the unibody. The arms are constructed of 2" and 1-1/2" diameter D.O.M. tubing, so go ahead and bash them against rocks and ledges because they can take the abuse and keep right on going!


The Rusty's Off Road 4.5" long travel suspension was developed for those that want the off-road performance of a long-travel kit but like to keep things low and would rather trim sheet metal to clear tires than go higher in lift height. This kit has all the same features of our taller long-travel kits, just in a shorter lift height. It takes you places other vehicles can't go; over logs, big boulders or over just about anything else on the trail. We have applied race technology and over 4 years of research and development to deliver a suspension system with enough articulation to keep your rig firmly planted even over the most radical terrain.

The control arms bolt to a new 1/4-inch thick laser-cut steel 3-piece cross member with a removable center section. This new design offers easier service and maintenance and is also surrounded by Rusty's frame reinforcement brackets. The 3/16" laser cut CNC formed reinforcement brackets are located on both the outside and the inside of the unibody and basically bond it together, tying the unibody and the new cross member together as one solid unit. This design distributes the extreme loads from the suspension over a much larger area of the unibody and assures many years of extreme four-wheeling without any structural damage to the unibody. The cross member's design does not reduce ground clearance and also drops the transfer case reducing driveline angles. Our optional Transfer Case Skid Plate can be easily added for further protection and support.

Due to the thinness of the Jeep unibody, we've designed our long-arm kits to be completely bolt-on Although it is possible to weld to the unibody, the longevity of the weld in questionable. The unibody is only 16 guage (.060 in.) and the heat of a weld stresses the thin metal. Even though the weld itself may not crack, the unibody around it may. While the unibody is welded from the factory, this was done with precision robotically-controlled welders with heat sensors to create welds that were much more precise than even the most skilled human welder. Our bolt-on systems are not only more durable than a weld-on system due to the extensive reinforcement involved, but they are also much easier to install. Our clamped/sleeved mounting system uses 1" x 3/16" thick tubes through the unibody, which creates a larger surface area that distributes stresses over a larger area than a weld-on installation. In addition, we use adjustable control arms that not only allow easy caster adjustment but also incorporate pivot points designed for suspension flex, which further eliminates stress on the unibody mounts.

• Front 4.5" coil springs
• Rear 4.5" leaf springs
• Front hydro performance shocks
• Rear hydro performance shocks
• HD track bar
• Rusty's Frame Brace
• Rusty's front sway bar disconnects
• Front & rear stainless steel braided brake lines
• Grade 8 U-Bolts
• Steel 6 degree shims

• HD cross member
• Adjustable long arm
• Adjustable radius arm
• Frame reinforcement (inner & outer)
• Hardware Kit 

NOTE: Though not required with 4.5" of lift, Rusty's recommends the use of a Slip Yoke Eliminator Kit to prevent driveline vibrations. This is available for only the NP231 and NP242 transfer cases. We also offer a Combo Kit that includes a quality CV driveshaft built by Tom Woods Driveline.

NOTE: 2000-2001 Jeep XJ Cherokee models require the use of Part# 52001180 Transmission Mount to be installed with this suspension system. 





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