The Jeep Cherokee XJ, a legend in the off-road community, is known for its boxy, utilitarian charm and incredible capability. However, as you upgrade to larger tires for better traction and ground clearance, the stock fender flares often become a limiting factor. They not only look dated but also fail to cover the aggressive tread of 31-inch or larger tires, leading to legal issues and unsightly mud spray. Enter the Bushwacker Flat Flares, a popular aftermarket solution that transforms the XJ’s appearance from a classic wagon into a modern, aggressive off-road machine.
This guide is your comprehensive resource for installing Bushwacker Flat Flares on your Jeep XJ in 2026. Whether you are a seasoned DIY mechanic or a first-time modifier, understanding the process, tools, and techniques is crucial for a professional finish. We will cover everything from preparation and cutting to final fitment and sealing, ensuring you achieve that sleek, rugged look without the headaches. By the end of this article, you will have the confidence and knowledge to complete this project in a weekend, dramatically upgrading your XJ’s stance and functionality.
Why Choose Bushwacker Flat Flares for Your XJ?
The decision to install flat flares is more than just an aesthetic one; it is a functional upgrade that addresses several key limitations of the stock Jeep XJ. The factory flares are rounded, plastic pieces that offer minimal tire coverage, typically accommodating tires up to 30 inches. Once you lift your XJ and mount 31-inch, 33, or even 35-inch tires, the stock flares leave a significant portion of the tire exposed. This not only looks awkward but is also illegal in many states, as tires must be fully covered by the fender. Bushwacker Flat Flares solve this by providing a much wider and flatter profile that extends outward, effectively covering larger tires and giving the vehicle a lower, wider stance.
Beyond legality and coverage, the flat flare design offers a distinct visual advantage. The sharp, angular lines of Bushwacker flares complement the XJ’s boxy body perfectly, creating a cohesive and aggressive look that is highly sought after in the off-road community. Unlike the bulky, rounded flares found on some other vehicles, the flat flares sit flush against the body and project outward, giving the XJ a purposeful, built-for-action appearance. This style is often associated with high-clearance builds and serious trail rigs, instantly elevating your Jeep’s visual appeal. Furthermore, the material used by Bushwacker is a durable, UV-resistant ABS plastic that is designed to withstand the abuse of rocks, branches, and mud, ensuring your investment lasts for years.
Finally, installing flat flares can actually improve your off-road performance. By trimming the factory fender wells to accommodate the new flares, you gain tire clearance. This allows your suspension to articulate fully without the tires rubbing against the metal body panels. This increased clearance is critical for crawling over, navigating deep ruts, and maintaining traction in challenging terrain. In essence, the Bushwacker Flat Flares are not just a cosmetic accessory; they are a-enhancing modification that allows you to fully utilize the capabilities of your lifted XJ and larger tires
Key Takeaways
- ✓ Bushwacker Flat Flares provide essential tire coverage for lifted XJs with 31-inch or larger tires, ensuring legal compliance and a clean look.
- ✓ The installation requires precise cutting of the factory fenders, making careful preparation and test-fitting critical for success.
- ✓ Using a high-quality automotive silicone sealant is mandatory to prevent rust and water damage between the flare and the body.
- ✓ The flat flare design dramatically improves the XJ’s appearance, giving it a wider, lower, and more aggressive off-road stance.
- ✓ Regular maintenance, including checkingeners and applying UV protectant, will keep the flares looking new and functioning properly for years.
Frequently Asked Questions
Do I need to cut my Jeep XJ’s fenders to install Bushwacker Flat Flares?
, cutting the factory metal fenders is a required part of the installation. The Bushwacker flares are designed to replace the stock flares and require you to trim the fender along a traced line to create a new, larger wheel opening. This is what provides the increased tire clearance and the sleek, flat profile. If you are not comfortable cutting metal, it is highly recommended to have the installation performed by a professional body shop or experienced off-road fabricator.
Bushwacker Flat Flares fit any year Jeep XJ (1984-2001)?
Yes, the Bushwacker Flat Flares are designed to fit all model years of the Jeep Cherokee XJ. The body dimensions and fender shapes are consistent across the entire production run. However, you should always verify the specific part number for your kit, as there may be slight variations in hardware or included accessories over the years. Always purchase a kit specifically listed for the Jeep XJ to ensure proper fitment.
Can I install these flares without removing the wheels?
While it is technically possible, it is strongly advised against. Removing all four wheels provides the necessary access to the fender wells for cutting, drilling, and installing the fasteners. Working with the wheels on is extremely, increases the risk of damaging the wheels or tires, and makes it nearly impossible to achieve a clean, accurate cut. Removing the wheels is a standard and essential step in the process.
What size tires can I fit with Bushwacker Flat Flares on a lifted XJ?
The tire size you can fit depends on your lift height and wheel backspacing. With a 3-inch lift and proper wheel offset, you can typically fit 31-inch tires with no rubbing. For 33-inch tires, a 4.5 to 6-inch lift is usually required. The flares themselves provide the clearance for the tire width, but the lift height determines the vertical clearance. It is best to research specific lift and tire combinations for the XJ to ensure a perfect fit.
How do I remove old silicone sealant if I need to replace a flare in the future?
Removing old silicone can be tedious but is manageable. Start by using a plastic razor blade or a panel removal tool to gently pry the flare away from the body. Once the flare is off, use a silicone remover solvent or isopropyl alcohol to soften the remaining sealant on the body. A 3M adhesive eraser wheel attached to a drill is highly effective for removing stubborn residue without damaging the paint. Take your time to avoid the paint.
Conclusion
Installing Bushwacker Flat Flares on your Jeep XJ is one of most visually and functionally rewarding modifications you can make. It transforms the classic Cherokee from a stock daily driver into a purpose-built off-road machine with a sleek, aggressive stance. By following this guide, you have learned that the process, while requiring patience and precision, is entirely achievable for a dedicated DIY enthusiast. From the initial preparation and careful cutting to the final sealing and mounting, each step contributes to a professional-grade result that will turn heads on the trail and the street.
Now that you have the knowledge, it is time to take action. Gather your tools, order your Bushwacker kit, and set aside a weekend for the project. Remember to work slowly, prioritize safety, and double-check your measurements before making any cuts. The result will be a dramatically improved Jeep XJ that not only looks incredible but also performs better off-road. Embrace the challenge, and enjoy the satisfaction of driving a truly customized and capable vehicle that reflects your personal style and dedication to the off-road lifestyle.
“Cars aren’t just machines. They’re freedom, memory, and a little bit of grease under your fingernails.”
I’m Theodore Roosevelt—though my friends just call me “Ted” (and no, I’m not related to the president, though I do share his love for adventure). I grew up in Detroit in the 1970s, back when the city was still the heart of the American auto industry. My first love was a rusted-out 1967 Mustang my father and I rebuilt in our garage when I was fifteen. That project taught me that cars have souls. After spending twenty years as a mechanic and another ten writing for magazines, I started this blog to help everyday drivers and weekend wrenchers feel confident under the hood. Whether you’re restoring a classic or just trying to keep your daily driver alive for one more winter, I’m here to help you get there.
