BARNES 4WD XJ Transfer Case Skid Installation Guide

: September 13, 2024
: BARNES 4WD

Table of Contents

BARNES 4WD XJ Transfer Case Skid
Installation Notes
Tools required
Contents of each box
Transfer Case Skid with Frame Stiffeners Install Notes
Professional Services Disclaimer
Read User Manual Online (PDF format)
Download This Manual (PDF format)

BARNES 4WD XJ Transfer Case Skid

Thank you for purchasing our XJ Transfer Case Skid!

Installation Notes

This product is designed to fit Jeep Cherokees 2 door or 4 doors 1984-2001 with the NP231 Transfer Case.
During installation some cutting and/or grinding may be required depending on your vehicle.
This transfer case skid is made to work with the factory cross member and factory control arms.
Further modifications may be required to work with any long arm kit that uses the factory crossmember.
This skid can fit with our XJ Frame Stiffeners. This is a very tight fit, some modifications may be necessary, and two jacks will be required to fit the skid completely.

Tools required

9/16” Socket and Wrench
11/16” Wrench
3/8” Drill Bit
17/32” Drill Bit
1/4” Drill Bit
Jack(s)
21/64” (.3281”) Drill Bit Frame Stiffener Installation

Contents of each box

Bill Of Materials For (BOM Part# and Description)

Transfer Case Skid with Frame Stiffeners Install Notes

If you do not have frame stiffeners installed continue to Step 1

The skid with frame stiffeners will be a very tight fit together. When jacking the skid in place, you may need another jack to fully place one side of the skid. Make sure the skid sits tight up against the front lip of the crossmember and tight and flat up underneath it.
A rubber mallet may be used to maneuver the skid to its proper place.
When installing the transfer case skid with frame stiffeners already on your Jeep, make sure all welds are ground flush with the stiffeners, leaving a clean flat surface.
3/8” thread forming screws will be used to install the skid instead of the 3/8” rivet nuts on the side of the frame (see Step 2). Using an 21/64” (.3281”) drill bit, drill out the 4 holes on the side of the frame, going through the stiffener and frame.
Starting with a pilot bit and working your way up to the correct size will help make sure the hole is straight and round to ensure a proper install of the thread forming screw.
Step 1:
With the Jeep parked on a level surface, jack the skid plate underneath the Jeep with the front lip tight up against the front of the crossmember. Ensure you are jacking the skid directly under the crossmember so the skid will sit flat underneath it.
Step 2:
Once you have checked the fitment of the skid, go ahead and start drilling pilot holes using the 1/4” drill bit for the 2 holes on each side of the uni- frame for the rivet nuts (see image below). If you have a transfer case drop, you will want to drill the pilot hole towards the top of the slot. If you do not have one, drill the pilot hole towards the bottom of the slot.
Step 3:
Make sure the skid is tight up against the front of the crossmember and drill two pilot holes using the 1/4” drill bit for the front two rivet nuts for the front lip bolts (see image above).
Step 4:
Remove the skid to prep and paint it.
Step 5:
Using a 17/32” drill bit, drill out the 6 pilot holes from Step 2 and 3. Be sure these are straight, clean holes to ensure the rivet nuts will install properly.
Step 6:
Using one of the 3/8” bolts, two 3/8” washers, and the provided 7/16” nut, as shown below, install the six rivet nuts. Push the rivet nut into the respected holes in the frame. With a 11/16” wrench, hold the 7/16” nut and using a 9/16” wrench or socket, tighten the bolt until the rivet nut is fully installed. The bolt will become very tight and there should be no wiggle or twist to the rivet nut.
Step 7:
Once the rivet nuts are all properly installed, jack the skid back in place. Thread the six 3/8” bolts and washers into the sides and front of the skid. Leave the four side bolts loose and snug
up the two front lip bolts so there is not gap between the front lip of the skid and crossmember.
Step 8:
Make sure the front lip of the skid is tight up against the crossmember. With a 3/8” drill bit, drill through the bottom two holes in the skid into the bottom and top of the crossmember. Make
sure to keep the drill in the center and straight so the bolt will sit flush. Loosely install the 3/8” flat head cap screws, washers, and nuts.
Step 9:
Fully tighten all bolts and nuts, starting with the front bolts on the skid lip, then the bottom flat head cap screws, and lastly the four side bolts.

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