'99 XJ roof rack/cross bars/slides removal procedures

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09-30-2019, 09:56 PM

soyjer

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Year: 1999

Model: Cherokee (XJ)

'99 XJ roof rack/cross bars/slides removal procedures

I have been unable to find detailed descriptions/pictures of how to remove the roof rack and/or cross bars from a later model XJ, so I am providing this info here:

NOTES:
REGARDING REMOVING END CAPS: The plastic "tabs" and "door panel fasteners" holding end caps on are nearly impossible to not break during their removal...but they are not required, because the front 25mm Torx rail screws retain the caps. Nevertheless, I chose to remove the FRONT end caps (instead of the rear end caps) because that way wind resistance would tend to keep the caps on rather than pull them off.
REGARDING RE-INSTALLING RAILS: Use Loctite Threadlocker Blue 242 or equivalent on 25mm Torx rail screws.

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These procedures work for a '99 XJ (see pictures to see if yours matches):

To ONLY remove CROSS BARS: Use a 25mm Torx driver to remove rail screws from ONE rail, then use a Phillips screwdriver to remove the 4 Phillips screws holding the cross bars to the slides, then pull the loose rail outward to release the cross bars.

To remove the ENTIRE RACK: Use a 25mm Torx driver to remove rail screws from both rails (then optionally use a Phillips screwdriver to remove the 4 Phillips screws holding the cross bars to the slides), then remove entire rack.

To remove one or both SLIDES from a rail, follow this procedure:

Use a 25mm Torx driver to remove rail screws from the rail (rearward screws can be merely loosened, if desired), then prop up the front end of the rail a few inches to gain access to the underside of the front end cap:

Use a <1/8" wide wide slotted screwdriver to push tiny plastic tab that helps hold cap in place out of the way (it's OK if it breaks off):

Use a door panel fastener removal tool/fork/forceps to remove plastic fastener that holds cap in place (it's OK if it breaks):

Optionally use a Phillips screwdriver to remove the Phillips screw holding the cross bar to the slide, then push the slide button and pull the slide off of the rail: