Hello - I have a 1991 XJ Sport (mfg'd 8/90) that I'm replacing the front axle on and had some questions. My current front axle is the vacuum-disconnect type and I will be obtaining and installing a D30 from a 1996 donor Cherokee. Currently the vehicle has a 6" lift and I am restoring it back to stock height.

1st question - Which track bar do I use? One from a 1991 or one spec'd for a 96. Or maybe a 1990? I noticed in my research that some are different lengths than others and I do want my axle to be centered during installation. Also, I noticed that the track bars are different between 1990 and 1991. My vehicle was mfg'd at the tail end of the 1990 production run but the VIN is classified as a 1991 model.

2nd question - when I bought the vehicle, the previous owner cut off the stabilizer bar brackets from the axle housing and discarded the sway bar. I am going to purchase another sway bar from a wrecking yard but don't know what size I should buy. There seems to be approximately 3 choices - 23, 24, and 26mm. Maybe even 28mm. Does anyone know which size the 90/91 Sport came with? Also, for the stabilizer bar links, will I need the 7-1/4" (up through 5/20/91) or 8-1/4" length (5/21/91 onward) since I'm switching to a later axle?

Thanks everyone for all the help and suggestions,

Paul

 

I'd try to get the sway bar off the donor 96 as well as the brackets that bolt the bar to the frame. Then you can just get new frame side bushings and end-links for a 96. The brackets probably will line up with the existing holes, but even if they don't you can always drill and tap new mounting holes and you should be good to go.

 

For swaybar size I'd just go with whatever you can find and then measure for the bushing. A thicker sway bar should result in flatter cornering (and possibly less flex off road) since it should be stiffer than a thinner one. If it was me I'd probably be replacing the suspension with some upcountry type pieces and would opt for the longer links of the two but a 1 inch difference in length at stock height won'tbe the end of the world either way.

 

Thanks Downs, I'll probably try to go with the thinner bar (if I can find it) for slightly softer cornering and remove the links for extended off-roading.

 

Thank you PatHenry. I have sourced a sway bar from another vehicle and will be installing it this month. Gonna grab some new bushings and links from Rock Auto and call it good.