While it is no big secret that Cavalier/Sunfire bucket seats are good swaps into YJs, the big problem with them is that the factory sliders are not long enough to mount to the seat frame without fabbing some sort of piece to connect them and will still inhibit full travel of the seat. Furthermore the factory YJ sliders aren't that great in terms of longevity. Since I really like my cavalier seats for the last few years I wanted a full length adjuster that increased fore and aft travel as well as being long enough to bolt to the seats factory locations.
I started by going to the pick a part yard to find and measure manual sliders in all types of suv's and vans. What I found was that Ford Windstar used a long manual adjuster that was the same design of the factory YJ's except longer and more robust in their build. Below is the build on them and maybe someone else can use it.
The sliders I got were the manual ones found on the Ford Windstar Minivans.
I paid $32 for the set at Parts Galore. When you pick them just unbolt the them from the risers (13mm socket) then simply unbolt the side brackets (13mm & 19mm) and take everything since it is easier this way.
Here is what you'll get
To start the first thing is to remove the adjusting handles (save the handles spring retainers) and mounting bracketry from the sliders.
I used a drill press to get the rivets out but a grinder would work as well.
There will be one stud at the rear of the seat side on the slider that will have to be removed (where the screwdriver is). The other two studs that attached to the Ford bracket you need to cut off. (NOTE: this is on the seat side of the track or the female portion of the silder)
Once all that is done, you're left with this:
Next you'll need to drill a hole to make a new stud where the track attaches to the YJ riser. (NOTE: these are for the flipping risers. if you have the fixed driver riser the measurement is a bit different. I didn't dig one out to measure that) The spacing is 11" front to rear. you will leave the front stud in the adjuster and measure to the rear. the front holes of the risers are oblong so you have a bit of leeway. mark and drill a 5/16" hole into the male portion of the adjuster.
On the seat side of the adjusters, the rear holes will need to be oblonged by about 3/16" to allow you get a straight line on the cavalier 14" apart mounting holes.
Now you have to install a stud in the new rear hole you drilled with a 5/16"x1" button head.
There is a bit of an angle so you have to make a temporary access door to be able to get the new stud in. i made two cuts:
Then flip up the tab:
Grind opposite sides of the bolt head to clearance the inside of the rail and install the new stud:
Next flatten the flap back down and weld it all back up:
NOTE: I used 1" length bolts to match what was on there. if you used a shorter bolt the access door could probably be skipped.
Place a weld on the head of the new stud to keep it from moving:
I then flipped the slider and put a few tacks on the bottom to ensure the new stud stays affixed. Then I chased the threads with a die to get rid of any spatter or damaged threads. now cut off the rear riser stud that was used in the windstar but is no longer needed (where the screwdriver is pointing).
The adjusting handle is too wide to fit between the sliders. Here is the unmodified adjusting handle:
The handle is just tubing, so take your tubing cutter and cut it in half:
Use some C-clamps and place the cut handle in the sliders and mark where they overlap then with your tubing cutter cut out the unwanted portion. I made sure that they were still a little wider in order to have some spring tension against the slider rails.
Clean up the ends of the tubing on the handle and get it set up to weld back together. You're going to want to make sure everything aligns to eliminate issues when you install them.
Weld it all back together. (you can see the section I removed from the slider)
Reinstall the adjuster handle onto the sliders with the factory spring clip retainers you removed at the beginning and re-lube the sliders with grease:
That's it. Reinstall the seats and rock on.