This is a wonderful posting, XJ4Ever! The right side power switch is currently defective on our '99 XJ Cherokee Sport 4-door, and this means the right window will not go down, the remote power door lock key fob will not activate the power locks, and the passenger has lost control of all switch functions. The wiring schematics are different for the two-door models and so are the symptoms for the switch failures. I need to get after that switch, I've already done the window lift motors and cable assemblies...both driver and passenger front.
The comment about factory routing of wires at the headliner may save many from doing the same—who would think! They need to make wiring schematics three-dimensional. The battery issue is a regular, as the wiring corrodes badly at the battery terminals and outward as you describe. Also, acid and debris build up at the battery hold-downs. You raise a very good point about not only voltage tests but, I would add, tests for resistance and voltage drop. Load tests by lamp-load method or a voltage drop test over distance would be smart.
As we know, the XJ Cherokee is a remarkable utility vehicle. They run seemingly forever with routine service. Their quirks are known, as are the fixes, and we learn to live with the nuisances. All things considered, the XJ Cherokee puts the "Volkswagen Beetle" (air-cooled engine era) myth to rest. Not only do we have the 4WD option, but the XJ will run to 300-plus thousand miles on the original axles and powertrain! The Beetle, despite all the hype and nostalgia, seldom saw 80-100,000 miles without a valve job, cylinder and piston replacement, a new clutch or two, suspension parts, replacement of all the control cables and a new exhaust system.
Credit to AMC for this remarkable, bold initiative, a compact SUV, likely the most durable production vehicle in history—especially outside the Rust Belt! With a unitized body that convinced us all, Dana beam axles front and rear, durable two-speed compact truck transfer cases, excellent transmission choices, plus a bulletproof inline six with seven main bearings and EFI from 1987-on, AMC/Jeep and Chrysler hit the mark!
The TBI 2.5L four, from day one in 1984, left an indelible impression, replaced in 1991 by the more efficient 2.5L Chrysler MPI engine...For those with an '84-'86 V-6 Cherokee or '86 V-6 Comanche pickup, the breakage prone G.M. 2.8L V-6 crankshaft and chronic rear main seal leaks can be eliminated with a G.M. direct replacement 3.4L V-6 RWD crate engine. Has anyone gone this route? Anyone tried a 302/5.0L Ford V-8 in an XJ?
Thanks for joining the discussion XJ4Ever, your post is a delight, and we look forward to more!