Index to cost effective XJ repairs - AUSJEEPOFFROAD.COM Jeep News Australia and New Zealand

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Old 12-11-2006
hillsjeep's Avatar
hillsjeep  hillsjeep is offline
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Join Date: Sep 2006
Location: adelaide hills
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Exclamation Index to cost effective XJ repairs

INTRODUCTION

After searching through the vast knowledge base on this forum and http://www.go.jeep-xj.info and with input from Gojeep, AussieRCbasher, Bugadifino, Xjdavid, Dan96xj, Steve F, Weeliebin, Snapey, Rodgebone, EwenM, Robert Davidson, DazzaXJ96, Gildo, Glenn, Jeepdownunder, Dsmit376, Jake, Kakadufong and Nakkas I have created this index to cost effective/best resolutions for the most common issues experienced in XJ Cherokees.

*******************************DISCLAIMER********* *************************
The following is not the views or opinions expressed by AJOR, but of personal collaborative know how of members through personal experience. Any problems caused by the info listed below is your own responsibility, and it is not the responsibility of AJOR, or AJOR members, to correct the situation. Thank you and enjoy.
************************************************** *************************



Please note: If you access Go-jeeps web site, please also visit the index page http://www.go.jeep-xj.info. This will keep the number of hits statistics accurate for that site.

I hope new XJ Cherokee owners find this information, from this forum & Gojeep, as useful as I have.

Send a PM to Hillsjeep or update http://www.ausjeepoffroad.com/forum/...ad.php?t=63979 if you identify any issues/repairs that should be added or notice any errors and I’ll update it.

Cheers
Phil


INDEX

1. Cracked header/Manifold
Headers on the Jeep 4.0Ltr motors have a tendency of cracking. This will not cause a major issue but is annoying. The best resolution for this is to install stainless steel extractors as welded repairs tend to crack again. This not only fixes the problem but also gives about a 10% performance boost. See: http://www.go.jeep-xj.info/HowtoExhuast.htm for more info. Make sure the new extractors are routed around the sump not under it to maximize ground clearance.

2. Leaking rear main seal
This is unlikely to be any worse than an annoying seep, however see http://www.go.jeep-xj.info/HowtoRearMain.htm for a DIY fix if you're sick of cleaning the driveway.

3. Leaking radiator
The stock radiator has plastic tanks, which may leak after about 150,000km. The best and cheapest resolution for this is to fit a full metal after market replacement. These are cheaper than replacing with the stock unit. Adrad make a quality unit, part number is JEE9001.C/A2. For details see: http://www.ausjeepoffroad.com/forum/...ad.php?t=64886
For installation info see: http://www.go.jeep-xj.info/HowtoRadiatorFitting.htm

4. Leaking or fragile heater tap/control valve
Due to the plastic used in the heater tap they may become brittle and fragile at about 150,000km. Either replace at this time or keep a spare in the glove box, for about $80.00 from Jeep or use VN commodore heater switch for half that price, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=57976 or http://www.ausjeepoffroad.com/forum/...ad.php?t=56582

5. Broken passenger side engine mount
Due to the heat from the manifold the passenger side engine mount can become brittle at about 100,000km. Best option is to replace this mount at this stage. Often the problem is not obvious until the engine mount is removed. Also be aware the US right hand mount is different to the Aus right hand mount, if ordering replacements from the US. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=57848 Also see these after market ones from the US. Due to their design they probably could be adapted to the Aus right hand side although this has not been tested as yet. http://www.jeepin.com/features/more/ or http://www.jeepin.com/features/motormounts/index.asp

6. Leaking transmission cooler hoses
Again not a major issue, but the plastic quick release connections on the transmission cooler hoses tend to deteriorate at about 150,000km and begin to seep. Replacements from Jeep are almost $400.00, however the problem can be easily fixed for about $20.00 using standard transmission cooler hose and good quality clamps. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=56527 or http://www.ausjeepoffroad.com/forum/...ad.php?t=64582

7. Cracked door hinges
Not a major issue if caught early enough. The welds on the drivers and passenger side door hinges often crack as the check strap doesn’t prevent the door from opening too far. For a DIY fix or prevention see: http://www.go.jeep-xj.info/HowtoDoorHinge.htm

8. Leaking water pump
All water pumps will eventually leak, however it appears after market water pumps have proven to last longer than stock water pumps. Stock water pumps seem to leak, after time, where the part number is stamped onto the body of the pump. Go-Jeep recommends Hesco water pumps, for more info see: http://www.go.jeep-xj.info/HowtoWaterpump.htm

9. Headlight switch fails
Headlight switches have been known to fail. The risk of this is greater if you have installed higher wattage globes. For more details see http://www.ausjeepoffroad.com/forum/...ad.php?t=64062 or to upgrade the headlight wiring loom to incorporate a relay and thus reduce the load on the switch see: http://www.ausjeepoffroad.com/forum/...ad.php?t=64823 or http://www.go.jeep-xj.info/HowtoHeadlightLoom.htm. Replacement switches are available from Poly4x4 or Jeep. It might pay to keep a spare in the glovebox.

10. Leaking oil filter adaptor
Another very minor, but annoying issue that is easily resolved by replacing the 3 "O" rings in the oil filter adaptor. It is also recommended to replace the stock "O" rings with high temperature "O" rings available from hydraulic specialists. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=62699. For a DIY fix see: http://www.go.jeep-xj.info/HowtoOilAdaptorOrings.htm

11. Faulty neutral safety switch
If your XJ sometimes doesn't start in park, the neutral safety switch may either be faulty or need cleaning. In worst cases they can also cause reversing lights and cruise control to fail. See http://www.ausjeepoffroad.com/forum/...ad.php?t=55430 or http://www.ausjeepoffroad.com/forum/...ad.php?t=55395 for more info or see http://go.jeep-xj.info/HowtoNSSrebuild.htm for a DIY fix.

12. Boot won't unlatch
Usually fixed by a clean or lube, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=54186 and http://www.ausjeepoffroad.com/forum/...ad.php?t=47092

13. Suspension sags in drivers side
An undocumented feature of the XJ is they tend to sag to the drivers side. This is fixed by adding coil spacers on the drivers side, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=51147 Excellent instructions on how to install a coil spring spacer are at http://www.trailmastersuspension.com...240_JC240G.pdf

14. Faulty Oxygen or Crank Angle Sensors
Oxygen sensors should be replaced at about 130,000km and Crank angle sensor at 150,000km. Faulty or dirty oxygen sensors can have a major impact on the performance of the vehicle as a false reading can cause the engine to run far to rich or lean. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=77858 or http://www.ausjeepoffroad.com/forum/...ad.php?t=63198 or http://www.ausjeepoffroad.com/forum/...ad.php?t=67153 For best price replacements see: http://www.ausjeepoffroad.com/forum/...ad.php?t=83864

A faulty Crank Angle sensor will prevent the engine from starting. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=56333 replacement instructions at: http://www.jeepforum.com/forum/showthread.php?t=197260

15. Overheating
Overheating can be an issue when the XJ is used to tow large loads uphill or are used offroad. A Thermo fan bypass switch is an inexpensive way of improving the vehicles cooling system in these situations. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=62485 or replace the stock fan with an electric fan see: http://www.ausjeepoffroad.com/forum/...ad.php?t=66510

16. Broken centre console lid
Not a major issue but extremely annoying when the plastic part, that the hinge screws on to, snaps and the lid is constantly finding its way to the rear passenger floor.
To fix take out the screws holding the hard inner liner of the lid to the soft padded top, undo the hinge from the console, unscrew the busted plastic bits.
Obtain some panel mount clips for self tapers, the kind you get in most speaker kits, they are spring steel flat clips that usually end up in the "spare" hardware tin.
Use the clips and the original screws to attach the hinge to the inner lid, re attach the inner to the padded lid, screw the hinge back onto the console and you're done.
1 Screw driver, 2 free clips, 10 minutes and you've fixed something that has been annoying you for months!

17. Central locking remote lost or broken
Replacement central locking remotes can be purchased directly from the US from "Keyless Ride" for a fraction of the price of the genuine unit. See their website http://www.keylessride.com/.
If you have a '97 pre-upgrade model XJ, order a '96 remote. The '97 pre-upgrade remotes come already programmed and are easily configured, however the post '97 upgrade models have to be configured by a dealership for about $88.00. To program a pre '97 model, see: http://www.ausjeepoffroad.com/forum/...d.php?t=71484&

18. Blocked or leaking PCV
The tube that goes from the top rear of the rocker cover to the inlet manifold or PCV (positive crankcase ventilation) should be checked every 30,000km to ensure it hasn't become blocked. If it is blocked the pressure in the engine will increase and cause oil leaks or blow oil back through the front pipe into the air box. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=62548 Part numbers for a 96 XJ are PCV K53030495 ($21.50) grommet K02946079 ($15.80). For a 96 XJ the grommet and PCV can just be pried out but in other models it may have to be rotated clockwise then removed.

19. Stretched transfer case chain
This is not a common problem, but may occur if you regularly tow heavy loads in 4WD. For details on how to replace the chain and where to source a replacement for a fraction of the dealership price, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=64854

20. Noisy or faulty A/C compressor
For a cheaper alternative to paying $1,200.00 for a Jeep replacement airconditioner compressor, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=56943

21. Upper & Lower control arm bushes
The upper and lower control arm bushes will become hard and inefficient at about 150,000km - 200,000km. This will start to be evident by a clunk when going over rough ground and in extreme cases could cause "death wobbles". Although a bit tricky these can be replaced with cheaper replacements from Quadratec. For more info see: http://www.ausjeepoffroad.com/forum/...ad.php?t=65510

22. Oil Filters
The Ryco Z9 filter can be used on the 4ltr petrol motor without any issues and is about 1/3 the price of the recommended Z89A filter. See: http://www.ausjeepoffroad.com/forum/...ad.php?t=66164

23. Transmission mount
If your transfer case is hitting its skid plate or if there is less than about 7mm clearance between the 2 then you may need to replace your transmission mount. This is about a 20 minute job and the mount costs about $50.00 plus postage from Wooders Garage. See: http://www.ausjeepoffroad.com/forum/...ad.php?t=67622

24. Idler pulleys squeeling
If you get a fanbelt or serpentine belt squeel, it may well be either of the idler pulleys. Jeep charge about $200.00 each but they can be purchased much cheaper from www.precisionparts.com.au. Part numbers are EP054(for the grooved) and EP057 (for the flat). See http://www.ausjeepoffroad.com/forum/...ad.php?t=62414 or can use idler pulleys from other cars much cheaper, see: http://www.ausjeepoffroad.com/forum/...ad.php?t=75927 and http://www.ausjeepoffroad.com/forum/...ad.php?t=78925

25. Bad fuel economy
If your fuel economy is above about 15L/100km read the posts in this thread for a list of items to check: http://www.ausjeepoffroad.com/forum/...ad.php?t=68389 and http://www.ausjeepoffroad.com/forum/...ad.php?t=75503

26. Rattle from rear of sump area
If you can hear a rattle coming from the rear of the sump area, check your torque to flex plate bolts are not backing out. For details see: http://www.ausjeepoffroad.com/forum/....php?p=786347&

27. Engine cutting while cornering
Several people have reported that their engines are cutting out when they corner. This is often caused by a failing fuel pump, however Roger has found one that is proving very hard to resolve. The following thread explores the numerous possible causes: http://www.ausjeepoffroad.com/forum/...ad.php?t=77657

28. Engine cutting out for no apparent reason
On several occasions this has been caused by the electical connector under the dash by the pedals failing. Sometimes there is evidence of heat in the connector. The following thread details where this connector is and shows a picture of one: http://www.ausjeepoffroad.com/forum/...ad.php?t=80873

29. Loss of 2nd gear
This is likely to be caused by a faulty solenoid. See this thread for the most cost effective replacement: http://www.ausjeepoffroad.com/forum/...ad.php?t=70296

30. Water pump failure
Another option to replacing the standard water pump is to replace it with an electric water pump: http://www.ausjeepoffroad.com/forum/...ad.php?t=93989

Last edited by hillsjeep; 03-04-2010 at 07:44 AM.
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