Headliner Replacement / Hardboard Headliner DIY

Factory headliner sags after 20+ years. Replace with 1/8" Masonite hardboard DIY (cheap, durable, $30), or buy a pre-made replacement, or have the factory board re-skinned.

The XJ factory headliner is foam-backed cloth glued to a fiberboard substrate. The foam adhesive fails around year 15-20 — the cloth droops, eventually flapping at speed.

DIY hardboard replacement (most common XJ fix):

1. Remove the existing headliner: pull sun visors, dome light, A/B/C pillar trim, grab handles. The headliner board drops down — you may need to slide it past the open rear hatch.
2. Use the old headliner as a template. Lay it on 1/8" tempered Masonite (Home Depot, ~$25 for a 4x8 sheet) and trace.
3. Cut with jigsaw. Round all edges with sandpaper.
4. Test fit in vehicle. Trim as needed for tight fit against windshield channel and pillars.
5. Cover with vinyl, headliner cloth, or fabric of choice using 3M Super 90 spray adhesive (heat-resistant). Or paint black with a flat texture spray for a quick rugged look.
6. Reinstall with original clips and trim.

Commercial replacement: order pre-formed headliner from Headliner Magic, RestoMod Air, or eBay sellers (~$200 with cloth installed). Stock-look replacement.

Upholstery shop reskin: drop off the old headliner board, get it re-skinned with new fabric/foam, $150-250. Best stock-look result.

While you're in there: install upgraded LED dome and map lights, run wiring for overhead aux switches or CB radio, add an overhead console (Rugged Ridge fits XJ).

Why it works

• cheap permanent fix
• hardboard is more durable than OEM
• can customize finish

Trade-offs

• takes a full day
• tight fit requires patience

Tools required

• jigsaw
• sandpaper
• trim tool
• spray adhesive

Parts

Part	Vendor	Est. price
1/8" Masonite hardboard 4x8 sheet	Home Depot / Lowes	~$25
3M Super 90 spray adhesive	3M	~$18
Headliner cloth (foam-backed) 60" x 60"	JoAnn / Amazon	~$30

Sources

• NAXJA - DIY Hardboard Headliner

Related

• All Jeep Cherokee XJ guides & tools
• Browse the full DIY database

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Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.

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