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 long travel suspension is going to be tough to beat! 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 Rusty's control arms bolt to a new 1/4-inch thick laser-cut steel 3-piece crossmember 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 sandwich it, tying the unibody and the new crossmember 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 crossmember's design does not reduce ground clearance and also drops the transfer case relieve 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 with the exception of the rear spring perches, which must be welded to the axle on the MJ. Although it is possible to weld to the unibody, the longevity of the weld in questionable. The unibody is only 16 gauge (.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" x3/16" 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.

The Rusty's heavy-duty over-the-knuckle steering system raises the tie rod bar over 3-1/2" and replaces all of the thin factory linkage with heavy-duty components designed to survive extreme trail use. However, raising the steering over the knuckles is not as simple as just bolting everything on top! There are many other things to consider in order to get the job done right, and Rusty's OTK system addresses them all with one complete package.

The Rusty's OTK Steering System consists of a tie rod with off-set rod ends, drag link, adjustable track bar, track bar frame mount, a weld-on track bar axle mount, stabilizer mount, and all the hardware. That's right, all of these components are required in order to get the job done safely and properly! Keeping the track bar and the drag link parallel is a must or you could have something that drives worse.

There are other kits on the market that use bent tubing, even .250 wall DOM. But once bent it is easier to bend this tubing on a rock or stump. Don't trust this type of "backyard" fab work. Forged Off Set rod ends that are forged this way are strong! Never trust a bent piece of tubing like you would something straight. Trust over 40 years of manufacturing and in the Jeep business, you will get the right parts needed.

The tie rod, drag link, and track bar are constructed of 1.5" x 0.250-wall DOM tubing. We use the highest-quality 3/4" rod ends with 5/8" diameter mounting holes. 3/4" Off Set Rod Ends are used on the tie rod for the extra clearance needed, while the drag link uses an offset at the axle and a conventional rod end at the pitman arm. The rod ends that we use are stronger than tie-rod ends and should last as long as tie-rod ends, even on daily driven vehicles. Score, BITD, SCCA, and just about every type of race vehicle use rod ends at all steering pivot points. Only Grade 8 hardware is included along with machined misalignment spacers that prevent rod end failure from over-articulation. All bolt-on parts have a durable black powder coated finish, while weld-on parts are raw steel.

KIT INCLUDES:
• Front 6.5" coil springs
• Rear 6.5" leaf springs
• Front hydro performance shocks
• Rear hydro performance shocks
• 3" drop pitman arm
• Rusty's XJ Over-The-Knuckle Steering System
• 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

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

NOTE: When lifting the XJ Cherokee 6 inches or more, Rusty's highly 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. 

PLEASE NOTE: THIS SUSPENSION KIT IS NOT COMPATIBLE WITH VEHICLES EQUIPPED WITH THE PEUGEOT MANUAL TRANSMISSION.

Steering Note: Note that 15" stock wheels and 15" aftermarket wheels with factory backspacing will not work with this system! All 15" wheels must have a maximum 4.5" backspacing; remember the higher the number for backspacing is not good, you can run 4.5, 4, 3.75, or 3.5, the factory 5.25" backspacing will not work. Anything set the tire in deeper will interfere with the steering. All 16", 17" or larger aftermarket wheels will not interfere.