Fix Sagging Doors on a Jeep Cherokee XJ (1997–2001) — The Ultimate Hinge Repair and Upgrade Guide

If you’re tired of slamming your Jeep Cherokee XJ doors to get them to close properly, you’re not alone. A sagging door is one of the most common issues facing 1997–2001 Jeep Cherokee owners. Fortunately, there’s a permanent solution that not only fixes the problem but upgrades the door hinges for a lifetime of smooth, sag-free operation.

In this guide, we’ll walk you through how to repair and upgrade worn-out door bushings using the Lots of Projects Door Hinge Upgrade Kit, and we’ll cover tools, techniques, and tips to ensure a professional result—even in your own garage.

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What Causes Jeep Cherokee Doors to Sag?

Over years of use, the factory hinge bushings wear out, causing the door to drop slightly when opening. This misalignment leads to a loud thud when closing, excessive wear on the door striker, and added stress on your door latch.

Common Symptoms of Sagging Jeep XJ Doors:

• Door latch misaligned from striker
• Door strikes Jeep body when closing
• Visible drop in door alignment when opening
• Door difficult to open or close

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Jeep Cherokee XJ Door Hinge Upgrade: Why It’s Worth It

The Lots of Projects Door Hinge Upgrade Kit solves these issues and more. This kit replaces your OEM bushings with oversized bushings and includes quick-release pins for easy future door removal.

Key Benefits:

• Permanently fixes sagging doors
• Restores proper door alignment
• Adds quick-release pins for easy door removal
• Optional install kit ensures perfect bushing alignment
• Fits all 1997.5–2001 Jeep Cherokee XJ models

⚠️ Note: Early 1997 models may have different hinge styles. Check yours before ordering.

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Tools & Supplies You’ll Need

Before starting your door hinge bushing replacement, gather the following tools:

• Rotary tool with metal cutting disc
• 7/16” drill bit and drill
• Sharp chisel (to remove rubber sleeves)
• Mini sledge hammer
• Locking pliers & pry bar
• Wire wheels and brake cleaner
• Painter’s tape and spray paint (to prevent rust)
• Optional: Lots of Projects Install Kit (highly recommended for easy bushing install)
• Safety glasses, gloves, and a soft bristle brush

🔗 Check out the full tool list and links at the bottom of this post.

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Step-by-Step Installation Instructions: How to Repair and Upgrade Your Jeep Cherokee Door Hinges

1. Remove Door Panels & Disconnect Wiring

Start by removing the interior door panel and fishing the wiring harness through the boot and into the door. This gives full access and prevents damage during cutting. Remove door check arm.

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2. Remove Rubber Pin Sleeves

Use a sharp chisel to split and remove the rubber sleeves surrounding the factory hinge pins. This prevents rubber from gumming up your cutting discs.

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3. Cut the Factory Hinge Pins

Using a rotary cutting tool, slice through the metal hinge pins. Cut the bottom hinge first to avoid twisting. Support the door with jack stands, a clamp table, or a friend.

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4. Drill Hinge Holes to Fit New Bushings

Drill the hinge holes to 7/16” using a high-quality drill bit. Use cutting fluid to avoid overheating. Drill vertically and carefully to maintain alignment.

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5. Clean and Prep for Paint

After drilling, use a wire wheel to remove debris and a degreaser like brake cleaner. Wash the area with soapy water and dry completely before painting.

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6. Paint to Prevent Rust

Mask the surrounding area and apply primer and color-matched spray paint to protect your work from corrosion.

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7. Install the New Bushings and Quick Release Pins

Install the alignment bushing in the hinge center, followed by the pivot bushings. Use the Lots of Projects Install Kit to press everything together precisely without damage.

After that, insert the quick release pins and confirm proper movement and clearance.

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Install Complete: Reinstall the Door and Enjoy

Once everything is in place, reinstall your door and check alignment. You should notice:

• No more sagging
• Smoother open/close
• Reduced wear on latch and wiring
• Easy removal for off-road use or maintenance

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🔩 What’s Included in the Lots of Projects Hinge Upgrade Kit?

This door hinge repair kit includes all premium components needed for one door:

• 2 Quick Release Pins
• 4 Heavy-Duty Pivot Bushings
• 2 Alignment Bushings with Grease Pocket

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📽️ Want to See It in Action?

▶️ Short Install Overview:

🎥 Complete Upgrade Kit Install Video:

Includes door wiring, cutting and drilling, and pressing in new bushings, our full video walks you through every detail.

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Pro Tips for a Perfect Install

• Cut the bottom hinge first to prevent twisting
• Use jack stands or a friend to support the door
• Drill slow and straight with lubrication
• Use brake cleaner + soap to prep surfaces for paint
• Don’t over-tighten bushings—only tighten until seated
• Add grease to the pin tip for smoother removal

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📦 Amazon Tool Link

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