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Jeep · Known Issues

2000 Jeep Wrangler Problems: 19 Known Issues

2000 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2000 Jeep Wrangler has 19 documented known issues, with 7 rated critical. The most serious are Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss ($250-$700 repair), In-Tank Fuel Pump Module Failure — Whine, Hard Start & No-Start ($200-$550 repair), 4.0L Crankshaft Position Sensor Thermal Failure — Random Stalling & Hot No-Start ($60-$250 repair), Front Frame Rust and Control Arm Bracket Corrosion ($800-$5,000 repair), Body Tub, Floor Pan & Body-Mount Rust (Torque Box Corrosion) ($400-$3,500 repair), Dana 35 Rear Axle Shaft C-Clip Failure ("Grenade") ($300-$2,200 repair) and 4.0L 0331 Cylinder Head Casting Cracking Between #3 and #4 Cylinders ($1,200-$2,600 repair). Across all issues with published estimates, repair costs range from $20 to $5,000. DIY maintenance guides at au7o.io.

In This Article

  • Wrangler Engine8
  • Wrangler Body/Panels2
  • Wrangler Fuel System2
  • Wrangler Drivetrain2
  • Wrangler Safety/Recalls1
  • Wrangler HVAC1
  • Wrangler Cooling1
  • Wrangler Steering1
  • Wrangler Electrical1
  • Recalls20
  • FAQ
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In This Article

  • Engine8
  • Body/Panels2
  • Fuel System2
Drivetrain
2
  • Safety/Recalls1
  • HVAC1
  • Cooling1
  • Steering1
  • Electrical1
  • Recalls20
  • FAQ
  • All 19 Known Issues

    Filter:
    ALL YEARS20262025202420232022202120202019201820172016201520142013201220112010200920082007200620052004200320022001200019991998199719951994

    When Issues Typically Appear

    Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss
    40K-120K
    Exhaust Manifold Cracking on 4.0L Inline-Six
    60K-150K
    Radiator End Tank Cracking and Coolant Leaks
    60K-160K
    Catalytic Converter Failure and Pre-Cat Efficiency Codes on 4.0L
    70K-180K
    Ignition Coil Rail Failure Causing Misfire on 4.0L
    70K-170K
    Blower Motor Resistor and HVAC Fan Speed Failure
    70K-180K
    Front Frame Rust and Control Arm Bracket Corrosion
    80K-200K
    050K100K150K200K mi

    On the 1997-2006 Jeep Wrangler, the crankshaft position sensor (CPS) on the 4.0L (and 2.5L) inline engines mounts on the transmission bellhousing and is exposed to severe heat soak. As it ages it develops intermittent thermal failure: the engine stalls without warning once hot, then refuses to restart until it cools, after which it runs fine again — a maddening, hard-to-replicate fault. Frequently the CPS fails with NO check-engine light and NO stored code, so it is commonly misdiagnosed. It is a top-searched TJ/early-Wrangler stalling complaint and a roadside-safety concern because the stall is sudden.

    This issue also affects: Chrysler LeBaron, Dodge Neon, Dodge Intrepid

    Common Symptoms

    • Engine stalls suddenly while driving, especially when hot
    • Will not restart until the engine cools, then runs normally
    • Cranks but no start when hot
    • Often no check-engine light and no stored DTC
    • Intermittent stumble/backfire
    • Hard starting in rainy/humid weather

    How to Fix

    When the engine stalls hot and won't restart, unplugging and reconnecting the CPS connector (near the back of the intake) often resets the PCM and the engine fires — a strong indicator the CPS is failing. Replace the crankshaft position sensor with a Mopar or NTK/NGK unit (Mopar 56027866AE for many 4.0L applications; 4727451AA covers 2003-2011 TJ/JK 3.8L & 4.0L). Avoid bargain aftermarket sensors — out-of-tolerance units cause repeat no-starts. No relearn required; verify with a hot road test.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 56027865AB crankshaft-position sensor
      OEMCrown 56027865AB

      Manual-transmission/early-engine sensor replacement after hot testing confirms signal dropout Fitment/availability: 1997-2004 Wrangler TJ 4.0L manual-transmission branch; the underlying application family also covers specified 1997-2002 …

      CarParts.com
    • Crown 4897321AA crankshaft-position sensor
      OEMCrown 4897321AA

      Early automatic-transmission sensor replacement after hot testing confirms signal dropout Fitment/availability: 1997-2002 Wrangler TJ 4.0L automatic-transmission branch. Confirm connector and transmission; not the manual or 2003-2006 bra…

      Quadratec
    • Standard Motor Products PC243 crankshaft-position sensor
      OEMStandard PC243 / Mopar cross 4727451AA

      Later TJ 4.0L sensor replacement after hot testing confirms crank-signal dropout Fitment/availability: Crosses Mopar 4727451AA for specified 2003-2006 Wrangler TJ 4.0L applications; verify transmission/connector and exact catalog fit bef…

      Auto Barn

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$60 - $250

    Research This Issue

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    Community Reported
    Medium ConfidenceVerifiedReviewed Jun 2026

    On the 1999-2002 Jeep Wrangler 4.0L I6 (PowerTech), the 4.0L inline-six heads carrying casting number 0331 (used on roughly 1999-2002 builds) were designed with enlarged intake/exhaust ports but left the deck wall between cylinders #3 and #4 too thin. Over high-mileage thermal cycling the head cracks in that area (visible through the oil-filler cap between the #3/#4 valve springs), often letting coolant weep into the combustion/oil galleries. It is one of the single most-searched TJ/LJ 4.0 failures.

    This issue also affects: Chrysler 300, Chrysler Aspen, Chrysler Cirrus

    Common Symptoms

    • Coolant loss with no visible external leak
    • Overheating on the highway
    • Rough idle or misfire
    • White exhaust smoke / sweet smell
    • Coolant in oil or oil in coolant on severe cracks

    How to Fix

    Confirm the casting number and inspect the deck between #3 and #4 through the oil filler. A cracked 0331 must be replaced. Chrysler revised the casting in 2003 with a thicker deck stamped 'TUPY' on the intake side; owners replace with a TUPY head or an aftermarket thick-deck 0331 casting (Clearwater/Titan/Clegg reman) plus a new head gasket (Fel-Pro 26224PT) and ARP or Mopar head bolts. Verify the correct casting before buying, as a plain 0331 replacement can crack again.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • HDPC new reinforced complete Jeep 4.0L cylinder head for 0331/0630/7120 replacement
      OEMHDPC reinforced universal Jeep 4.0L head

      Crack-resistant replacement head after the original 0331 casting is confirmed cracked Fitment/availability: Published 1991-2007 Jeep 4.0L universal reinforced casting with thickened deck/water jackets; enter year/make/casting and confirm…

      Heavy Duty Parts Company
    • ARP 146-3601 Jeep 4.0L inline-six cylinder-head bolt kit
      OEMARP 146-3601

      Use only with the included ARP instructions; do not apply factory torque-to-yield values to ARP hardware.

      Super Shops

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$1,200 - $2,600

    Research This Issue

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler 4.0L I6, a very common TJ Wrangler problem is cracking of the 4.0L exhaust manifold/header, especially around the collector and expansion joints. Repeated heat cycling and engine movement fatigue the factory manifold, leading to ticking noises on cold start, exhaust smell, and sometimes failed emissions tests. Owners frequently report the noise being mistaken for valvetrain tick until the crack worsens.

    This issue also affects: Chrysler 200, Chrysler Pacifica, Chrysler PT Cruiser

    Common Symptoms

    • Ticking noise on cold start
    • Exhaust leak smell in engine bay
    • Noise decreases as engine warms up
    • Failed emissions inspection
    • Visible soot near manifold crack

    How to Fix

    Diagnosis is usually done with a cold-start listen test, smoke test, or visual inspection from underneath and around the manifold welds. The long-term fix is replacement with an updated manifold/header design that includes better flex sections and new hardware/gaskets. Shops often recommend replacing manifold bolts/studs at the same time because broken fasteners are common on removal.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 53010196 front/left exhaust manifold section
      OEMCrown 53010196

      Replace a confirmed crack in the front/left half of the two-piece manifold Fitment/availability: 2000-2006 Wrangler TJ/LJ with 4.0L I6; front section only. Confirm emissions/downpipe arrangement and do not substitute a 1997-1999 one-piec…

      Quadratec
    • Crown 53010199 rear/right exhaust manifold section
      OEMCrown 53010199

      Replace a confirmed crack in the rear/right half of the two-piece manifold Fitment/availability: 2000-2006 Wrangler TJ/LJ with 4.0L I6; rear section only. Confirm emissions/downpipe arrangement and do not use the old 53010198 salvage lis…

      Quadratec
    • Fel-Pro MS93094 intake/exhaust manifold combination gasket
      OEMFel-Pro MS93094

      Renew the shared head-to-intake/exhaust seal whenever the manifolds are removed Fitment/availability: Jeep 4.0L application including the 2000-2006 Wrangler issue range; verify vehicle fitment and inspect sealing surfaces before installa…

      AutoZone
    • Dorman 03408 exhaust-manifold mounting hardware kit
      OEMDorman 03408

      Replace seized, broken, stretched or missing manifold-to-head hardware during the confirmed repair Fitment/availability: 1997-2006 Wrangler/TJ application within Dorman's 1991-2006 Jeep coverage; 3/8-16 and 3/8-24 hardware. Inventory is …

      PartCatalog

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Owner tips & cautions

    • TipCheck for the leak on a cold engine; manifold cracks are often loudest for the first 30-90 seconds after startup.
    • TipIf replacing the manifold, inspect motor mounts too, because excessive engine movement can accelerate cracking.
    Typical repair cost:$400 - $1,200

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    On the 1997-2001 Jeep Wrangler 4.0L I6 (PowerTech), the 4.0 routes oil through a cast oil-filter adapter housing bolted to the block behind the filter, sealed by a set of rubber O-rings. The O-rings harden and shrink with age/heat, producing a persistent oil leak on the passenger side of the block that runs down the bellhousing and is very commonly misdiagnosed as a rear main seal. A classic high-mileage TJ/XJ/ZJ oil leak.

    Common Symptoms

    • Oil leak on passenger side of the block
    • Oil dripping from bellhousing area
    • Oily grime around the oil filter
    • Low oil level between changes

    How to Fix

    Replace the adapter O-ring set — Mopar/Crown kit 4720363 (three O-rings) for 93-01 4.0 applications. The housing is retained by a large T60 Torx through-bolt; back it out from underneath with the filter left on the housing so it can't spin on the roll pin. Some owners eliminate the adapter and run a narrow spin-on (Fram PH3614-style) filter directly on the block. Clean both mating faces before reassembly.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Genuine Mopar 4720363 oil-filter adapter O-ring seal set
      OEMMopar 4720363

      Complete adapter reseal after leak tracing proves oil originates at the adapter-to-block or through-bolt seals Fitment/availability: Seller's exact 1993-2001 Jeep Wrangler/Grand Cherokee 4.0L listing with 2001 Wrangler fitment shown. Mat…

      eBay — Quirk Parts

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$40 - $400

    Research This Issue

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    Community Reported
    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 1994-2006 Jeep Wrangler 4.0L I6 (PowerTech), a leaking rear main seal is nearly universal on high-mileage 4.0 Wranglers — the two-piece crankshaft seal hardens and weeps oil at the back of the block, dripping onto the bellhousing and often collecting at the transmission. It is one of the most-searched 4.0 oil leaks and is frequently confused with an oil-filter-adapter or oil-pan-gasket leak.

    Common Symptoms

    • Oil drip at back of engine / bellhousing
    • Oil spots under the transmission bell area
    • Low oil level between changes
    • Oily film on skid plate

    How to Fix

    Because the 4.0 uses a two-piece rope/lip seal, the rear main can be replaced without pulling the transmission — drop the exhaust, oil pan, and main bearing support/cap to swap the upper and lower halves (Fel-Pro BS40183). Refresh the oil pan gasket (Fel-Pro OS34308R) at the same time. Correct RTV at the seal parting lines is critical to avoid a repeat leak.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Fel-Pro BS40612 two-piece rear-main seal set
      OEMFel-Pro BS40612

      Pre-redesign rear-main seal replacement after leak tracing confirms the crank seal Fitment/availability: 1994-1999 Wrangler 4.0L branch. Do not use on the 2000-2006 redesigned rear-main cap/seal application.

      JEGS
    • Fel-Pro BS40183 two-piece rear-main seal set
      OEMFel-Pro BS40183 / Mopar cross 5018594AB

      Post-redesign rear-main seal replacement after leak tracing confirms the crank seal Fitment/availability: 2000-2006 Wrangler/TJ 4.0L application. Do not use on the 1994-1999 pre-redesign branch.

      SD Parts
    • Fel-Pro OS34308R one-piece molded oil-pan gasket set
      OEMFel-Pro OS34308R / AutoZone 74438

      Oil-pan reseal required when the pan is removed for the confirmed rear-main repair Fitment/availability: Application-specific Jeep 4.0L pan-gasket family spanning the issue years; confirm exact YMM before purchase.

      AutoZone
    • Permatex Ultra Grey 82194 RTV gasket maker, 3.5 ounces
      OEMPermatex 82194 / AutoZone 306563

      Do not coat the rear-main seal lip or substitute it for anaerobic sealant where the factory procedure requires a different chemistry

      AutoZone

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$200 - $700

    Research This Issue

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    Community Reported
    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler 4.0L inline-six, tJ Wranglers with the 4.0L frequently develop catalytic converter deterioration, especially on higher-mileage vehicles and 2000-2006 emissions configurations using multiple converters/pre-cats. Owners commonly report a check-engine light with catalyst-efficiency codes, sulfur smell, rattling substrate, or loss of power if the converter begins to clog. This issue is well documented in owner complaints, repair databases, and Jeep service information.

    This issue also affects: Chrysler 200, Dodge Dart, Dodge Durango

    Common Symptoms

    • Check engine light
    • P0420 or catalyst efficiency codes
    • Rattling from catalytic converter
    • Sulfur or rotten egg smell
    • Reduced power at higher RPM
    • Failed emissions inspection

    How to Fix

    Diagnosis involves checking for P0420/P0432-type efficiency codes, verifying upstream engine tune issues are not causing converter damage, and measuring exhaust backpressure or temperature differential if restriction is suspected. Repair is replacement of the failed converter assembly and any lazy O2 sensors if needed. Misfires, oil burning, or rich-running conditions should be corrected first so the new converter is not quickly damaged.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • MagnaFlow MF23297 Federal/EPA direct-fit rear catalytic-converter assembly
      OEMMagnaFlow 23297 / etrailer MF23297

      Not CARB compliant and retailer states it cannot be shipped to or used in California, Colorado, Maine or New York; verify the emissions labe

      etrailer
    • aFe Power 47-48003 Federal direct-fit front catalytic-converter assembly
      OEMaFe Power 47-48003 / Quadratec 17121-1000

      Confirm wheelbase, emissions l

      Quadratec

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$600 - $1,800

    Research This Issue

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    Community Reported
    High Confidence

    On the 2000-2006 Jeep Wrangler 4.0L inline-six, the 4.0L coil-rail ignition system used on TJ Wranglers is known to develop internal failures that cause intermittent or persistent misfires. Owners report rough idle, hesitation, flashing check-engine lights, and cylinder-specific misfire codes, often after moisture intrusion, age, or heat exposure. Because the rail serves all cylinders, diagnosis can be less straightforward than on engines with individual plug wires.

    This issue also affects: Chrysler 300, Chrysler Aspen, Chrysler Cirrus

    Common Symptoms

    • Rough idle
    • Engine stumble under load
    • Flashing check engine light
    • Cylinder-specific misfire codes
    • Poor fuel economy

    How to Fix

    Scan for misfire codes, inspect spark plugs, and verify injector and compression health before condemning the coil rail. If the rail is weak or cracked, replacement of the coil rail assembly and spark plugs is the typical fix. Dielectric grease on the boots and ensuring the valve cover area stays dry can help longevity.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Genuine Mopar 56041476AB ignition coil rail
      OEMMopar 56041476AB

      Replace a test-confirmed weak, cracked or internally failed coil rail Fitment/availability: 2000-2006 Wrangler TJ/LJ with 4.0L inline-six; not 2.4L/2.5L distributor or individual-coil systems. Confirm wiring and paired-cylinder evidence …

      Quadratec
    • Champion Copper Plus 412 / RC12LYC spark plug
      OEMChampion 412 / RC12LYC

      Replace worn or fouled correct-spec plugs as a set of six after confirming the vehicle's emission-label specification Fitment/availability: 0.035-inch copper plug commonly specified for the 4.0L waste-spark application; quantity six requ…

      AutoZone

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$180 - $500

    Research This Issue

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    Community Reported
    High Confidence

    On the 1994-2006 Jeep Wrangler 4.0L I6 (PowerTech), one of the most common 4.0 oil leaks: the valve cover gasket hardens and seeps, typically worst at the rear of the head, leaving oil and grime down the back of the block and sometimes dripping onto the exhaust (burning-oil smell). Frequently mistaken for a more serious rear main or head-gasket leak.

    Common Symptoms

    • Oil seepage down the back/side of the engine
    • Burning-oil smell after driving
    • Oil pooling in spark-plug tube area
    • Grime buildup on the head

    How to Fix

    Replace the valve cover gasket — Fel-Pro VS50458R (or VS50522T, which has integrated bolt eyelets). Reuse the metal spacer inserts, replace the rubber grommets, clean both mating surfaces, and do NOT over-torque the bolts. Later steel-cover TJ/LJ 4.0s use the eyelet-style gasket. A cheap DIY fix.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Fel-Pro VS50458R one-piece valve-cover gasket set with grommets
      OEMFel-Pro VS50458R / AutoZone 579204

      Valve-cover reseal after leak tracing and cover inspection confirm the perimeter gasket Fitment/availability: Later Jeep 4.0L molded-rubber cover family cross-referencing Mopar 53020758AA/AC; confirm exact Wrangler YMM/cover, particularl…

      AutoZone

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$30 - $300

    Research This Issue

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    Community Reported
    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler, rust-through of the TJ frame, especially near the lower control arm mounts, skid plate area, and rear trailing arm sections, is one of the most serious age-related Wrangler problems. In rust-belt states, owners report perforation severe enough to affect suspension mounting integrity and vehicle safety inspections. Corrosion often starts from the inside of the boxed frame where mud and moisture collect, so the outside can look better than the structure actually is.

    Common Symptoms

    • Visible rust holes in frame
    • Flaking metal near control arm mounts
    • Failed safety inspection
    • Loose or compromised suspension brackets
    • Crunching metal when probing frame

    How to Fix

    A proper inspection requires tapping/probing the frame, checking inside drain holes with a borescope, and closely examining control arm and skid plate mounting areas. Minor corrosion can sometimes be treated and reinforced, but perforated sections usually require welded frame repair caps or full frame replacement. Preventive treatment includes internal frame coating and regular flushing of debris from boxed sections.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Rust Buster RB4011L/R front control-arm frame repair section
      OEMRust Buster RB4011L / RB4011R

      Professional weld-in structural repair after full mapping confirms corrosion is contained within the compatible front control-arm section Fitment/availability: 1997-2006 Wrangler TJ/LJ, select left RB4011L or right RB4011R to match the d…

      Quadratec

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Owner tips & cautions

    • TipInspect the frame from the inside out; many owners find the worst rust by looking through factory holes near the skid plate and control arm brackets.
    • TipAfter repairs, flush the frame regularly and apply an internal corrosion inhibitor before winter driving.
    Typical repair cost:$800 - $5,000

    Research This Issue

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    High Confidence

    On the 1994-2006 Jeep Wrangler, distinct from frame corrosion, the steel body tub rusts from the inside out on older Wranglers, especially in salt regions. The spot-welded body-mount channels ('torque boxes') under the floor, the floor-pan seams, and the rocker areas trap moisture and rot around the three body mounts on each side — a critical structural/search topic for buyers of high-mileage TJ/YJ examples.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • Rust/holes in floor pans
    • Rotted body-mount channels
    • Soft/perforated rocker panels
    • Body shifting or squeaks over the frame
    • Water intrusion into cabin

    How to Fix

    Inspect all body mounts and floor seams; light surface rust can be wire-wheeled, treated with a rust converter, and protected with Fluid Film. Rotted torque boxes/floor pans require cut-out and weld-in replacement panels (e.g. NIXFACE full tub body-mount repair kit, C2C Fabrication weld-in floor and torque-box panels) plus new body-mount bushings. Address before any lift or armor install.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Key Parts 0485-317/318 left and right full-length TJ torque-box/floor-support pair
      OEMKey Parts 0485-317/318

      Weld-in structural repair for perforated full-length body-mount channels on both sides Fitment/availability: 1997-2006 Wrangler TJ only; 16-gauge pair with seat, roll-bar and body-mount nuts. Requires professional measurement, bracing, c…

      Carolina Classic Trucks
    • Crown 55176180K complete rubber body-mount kit
      OEMCrown 55176180K

      Renew worn or contaminated body isolators after the TJ torque-box/floor structure is repaired Fitment/availability: 1997-2006 Wrangler TJ and 2004-2006 LJ; includes 11 retainers and 22 mounts but not replacement body-mount bolts. Not a Y…

      Quadratec
    • Key Parts 0480-220 complete YJ floor-pan assembly with supports and torque boxes
      OEMKey Parts 0480-220

      Freight item; not interchangeable with TJ panels.

      CarParts.com
    • Energy Suspension 2.4105 YJ body-mount and radiator-support bushing kit
      OEMEnergy Suspension 2.4105

      Renew YJ body mounts after the repaired structure has been measured and restored Fitment/availability: 1987-1995 Wrangler YJ polyurethane kit; select color. Not a TJ kit, not an OE-rubber equivalent and not a substitute for rotted torque…

    • Fluid Film AS11 solvent-free lanolin corrosion inhibitor, 11.75-ounce aerosol
      OEMFluid Film AS11 / AutoZone 253803

      Post-repair protection inside seams/channels and preventive coating on remaining sound metal Fitment/availability: Generic non-drying corrosion inhibitor. Apply only after welding/refinishing is complete and according to product directio…

      AutoZone

    As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

    Typical repair cost:$400 - $3,500

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    Community Reported
    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 1997-2006 Jeep Wrangler, the in-tank fuel pump module (pump, sending unit, and level float) wears out on high-mileage TJ Wranglers, producing a loud whine from the tank, hard starting, stalling, and eventual crank-no-start as fuel pressure drops. A top-searched TJ fuel-system failure, sometimes accompanied by an inaccurate fuel gauge from the same module.

    This issue also affects: Alfa Romeo Giulia, Alfa Romeo Stelvio, Chrysler 200

    Common Symptoms

    • Loud whine/hum from the fuel tank
    • Extended cranking / hard start
    • Stalling under load or when low on fuel
    • Crank but no-start
    • Erratic fuel gauge

    How to Fix

    Replace the complete fuel pump module (not just the motor) after confirming low fuel pressure. Match the tank size: 97-02 TJ 19-gallon uses modules such as Bosch 67756 / Omix; 03-04 TJ 2.4L/4.0L uses Crown 5093788AA. Inspect the tank and strainer, and replace the pump-to-tank seal. Verify 15- vs 19-gallon tank before ordering.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 5012951AD complete fuel-pump/level module
      OEMCrown 5012951AD

      Replace a confirmed failed complete module in the small-tank early branch Fitment/availability: 1997-1999 Wrangler TJ 2.5L or 4.0L with 15-gallon tank only; verify tank capacity and connector before ordering.

      Bernie's Jeep Parts
    • T-Rex TREXTJFM-2 complete 19-gallon fuel module replacing 5012952AD
      OEMT-Rex TREXTJFM-2 / replaces 5012952AD

      Replace a confirmed failed complete module in the 19-gallon early branch Fitment/availability: 1997-2002 Wrangler TJ 2.5L or 4.0L with 19-gallon tank only; verify tank capacity, connector and sender resistance before ordering.

      T-Rex Auto Parts
    • Crown 5093788AA complete fuel module
      OEMCrown 5093788AA / Mopar 5093788AB

      Replace a confirmed failed complete module in the 2003-2004 branch Fitment/availability: 2003-2004 Wrangler TJ/Unlimited 2.4L or 4.0L; select exact 5093788AA/AB module and verify VIN/connector. Do not use an early 15- or 19-gallon module.

      Crown/Jeep specialty retailer
    • Crown 5161335AF complete fuel module with O-ring
      OEMCrown 5161335AF

      Replace a confirmed failed complete module in the 2005-2006 branch Fitment/availability: 2005-2006 Wrangler TJ/Unlimited 2.4L or 4.0L; verify VIN/connector and sender resistance.

      Somar 4x4
    • Mopar 52018808 fuel-pump/level-module seal
      OEMMopar 52018808

      Some complete modules already include a seal, so do not duplicate unnecessarily.

      Quadratec
    • Crown 55366298AA fuel-module O-ring
      OEMCrown 55366298AA

      Renew the tank-to-module seal when servicing the late TJ module Fitment/availability: 2005-2006 Wrangler TJ/Unlimited; later-style O-ring. Some complete modules already include it, so check kit contents before ordering.

      Quadratec

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    Typical repair cost:$200 - $550

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 1997-2006 Jeep Wrangler, the throttle-body-mounted TPS wears and produces an erratic voltage signal, causing high/hunting idle, stalling at stops, hesitation or bucking on acceleration, and — on automatics — erratic or harsh shifting. A very common, high-search TJ driveability complaint that often illuminates the check-engine light.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • High or hunting idle
    • Stalling when coming to a stop
    • Hesitation/bucking on acceleration
    • Erratic or harsh automatic shifting
    • Check-engine light

    How to Fix

    Confirm with a scan tool (P0121/P0122/P0123) and swap in a quality TPS — Mopar 04874371AC (superseded by 68433984AA). Owners strongly recommend Mopar, Standard Ignition, or NGK over cheap economy sensors, which frequently fail again. Verify closed-throttle voltage and idle relearn after install.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Omix 17224.04 throttle-position sensor
      OEMOmix 17224.04

      Replace a circuit-tested TPS on the early throttle-body branch Fitment/availability: 1997-2001 Wrangler TJ 2.5L or 4.0L; verify connector and throttle-body/tang geometry before ordering.

      Advance Auto Parts
    • Genuine Mopar 68404428AA throttle-position sensor
      OEMMopar 68404428AA

      Replace a circuit-tested TPS on the later throttle-body branch Fitment/availability: 2002-2006 Wrangler TJ/Unlimited with 2.4L or 4.0L as cataloged; verify VIN and connector.

      MoparPartsGiant

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    Typical repair cost:$50 - $220

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 1994-2006 Jeep Wrangler, the Dana 35 rear axle fitted to most non-Rubicon YJ/TJ Wranglers uses a C-clip design: each semi-float axle shaft is retained inside the housing only by a C-clip seated in the differential. If a shaft snaps — common with 33-inch-plus tires, a locker, or aggressive trail use — the wheel and outer shaft can slide completely out of the housing ("grenade"), damaging brakes and potentially separating the wheel while driving. A top-searched off-road reliability weak point.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • Sudden loss of drive to one rear wheel
    • Wheel shifting outward or falling out
    • Clunk/bang from rear axle under load
    • Metal shavings in diff fluid

    How to Fix

    For stock use, keep tire size sane and inspect shafts/seals. For lifted or wheeled rigs, upgrade to chromoly/one-piece shafts, install a C-clip eliminator kit, or swap to a Dana 44 / Ford 8.8 rear axle. Crown/Omix replacement Dana 35 C-clips and shafts (e.g. Crown 5012826AA shaft) are available for repair; a broken shaft requires pulling the diff cover to retrieve the clip and inner stub.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 5252505 Dana 35 rear axle-shaft C-clip
      OEMCrown 5252505

      Replace a lost, distorted or damaged stock-style retainer during a confirmed Dana 35 shaft repair Fitment/availability: 1994-1995 YJ and 1997-2006 TJ with Dana 35 C-clip rear axle; sold individually.

      FinditParts
    • Crown RT23001 27-spline chromoly Dana 35 axle-shaft pair
      OEMCrown RT23001

      Stronger direct-replacement shaft pair for the compatible early drum-brake Dana 35 branch Fitment/availability: 1994-1995 YJ and 1997-2002 TJ with Dana 35, factory 27-spline carrier and drum brakes; includes bearings, seals and retainers…

      JEGS

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    Typical repair cost:$300 - $2,200

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 1994-2006 Jeep Wrangler, the NP231 (Command-Trac) transfer case in YJ/TJ Wranglers uses a slip-yoke rear output. The rear output shaft seal is a chronic leak point — the exposed slip yoke picks up grit and rust that scores the seal, and a worn tail-housing bushing lets the yoke move and tear the seal. Result is ATF weeping from the back of the t-case, a very common older-Jeep drivetrain search.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • ATF/gear-oil leak at rear of transfer case
    • Fluid on the rear driveshaft and skid plate
    • Low transfer case fluid
    • Driveline vibration if bushing worn

    How to Fix

    Replace the rear output shaft seal (National/SKF 18662 or equivalent) after cleaning/inspecting the yoke and tail bushing; tape over the retainer-clip groove during install so the seal lip glides past it. If the tail bushing is worn or a lift causes driveline vibration, install a Slip-Yoke Eliminator (SYE) kit with a fixed yoke and a CV driveshaft (Rugged Ridge/Omix 18676.62 housing seal). A basic seal fix is inexpensive.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Genuine Mopar 4638904 rear output seal
      OEMMopar 4638904

      Reseal the stock NP231 rear output after inspecting the yoke and tail bushing Fitment/availability: 1994-1995 Wrangler YJ with the stock NP231 slip-yoke output; confirm transfer-case tag and VIN.

      MoparPartsGiant
    • Genuine Mopar 4798117 output-shaft seal
      OEMMopar 4798117

      Reseal the stock external-slip-yoke rear output after confirming the housing and transfer case Fitment/availability: 1997-2006 Wrangler TJ with stock NP231 configuration; exclude 2003-2006 Rubicon NV241OR and any vehicle already converte…

      MoparPartsGiant
    • Rugged Ridge 18676.60 NP231 slip-yoke eliminator kit
      OEMRugged Ridge 18676.60

      Optional fixed-yoke conversion when inspection finds a worn stock tail housing or lift-related driveline geometry requires it Fitment/availability: 1988-2006 YJ/TJ/Unlimited with NP231 only; not NV241OR. Requires a separately measured lo…

      Quadratec

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    Typical repair cost:$20 - $400

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler, a common TJ/LJ Wrangler failure is the steering column clock spring wearing out internally, which breaks electrical continuity to the driver airbag, horn, and cruise-control switches. Owners typically report an illuminated airbag light along with an inoperative horn and cruise control. This was widespread enough to generate many owner complaints and a Jeep recall campaign on certain vehicles.

    Common Symptoms

    • Airbag warning light illuminated
    • Horn inoperative
    • Cruise control stops working
    • Intermittent steering wheel switch functions
    • SRS fault stored

    How to Fix

    Diagnosis usually starts by confirming loss of horn/cruise functions and scanning the airbag module for driver squib or clock spring circuit faults. The repair is replacement of the clock spring assembly with the updated part, followed by steering wheel centering and clearing any stored airbag faults. If the steering wheel has been removed previously or the front end alignment is off-center, the new clock spring must be installed in its centered position to avoid repeat failure.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Dorman 525-118 airbag clockspring without cruise control
      OEMDorman 525-118

      Restore the confirmed clockspring circuit on the 2000 no-cruise branch Fitment/availability: 2000 Wrangler/TJ without cruise control; crosses 56009070/56047103 family. Confirm equipment and VIN; not the speed-control version.

    • Crown 56047103AB clockspring without speed control
      OEMCrown 56047103AB

      Restore the confirmed clockspring circuit on the 2001-2002 no-speed-control branch Fitment/availability: 2001-2002 Wrangler TJ without cruise/speed control. Do not use on vehicles equipped with cruise or on 2003-2006.

      Quadratec
    • Dorman 525-119 airbag clockspring
      OEMDorman 525-119

      Restore the confirmed clockspring circuit on the later TJ branch Fitment/availability: 2004-2006 Wrangler/TJ and OE cross 56047144AB-AE. The 2003 catalog uses 56047144AA and must be sourced/confirmed separately; do not silently extend th…

      JEGS

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    Typical repair cost:$250 - $700

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    High Confidence

    On the 1997-2006 Jeep Wrangler, the heater core inside the dash-mounted HVAC box develops leaks on high-mileage Wranglers, releasing a sweet coolant smell in the cabin, an oily film that fogs the windshield, and eventually a wet passenger-side carpet with unexplained coolant loss. A common older-Jeep HVAC search due to how labor-intensive the fix is.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • Sweet coolant smell inside the cabin
    • Greasy film fogging the windshield
    • Wet/damp passenger-side carpet
    • Unexplained coolant loss
    • Weak or no heat

    How to Fix

    Replace the heater core — the job requires removing the console, full instrument panel/dash, and steering column to extract the HVAC housing (roughly a full day of labor). As a stopgap to keep driving, the two firewall heater hoses can be joined with a coupler (loses heat/defrost). Pressure-test the cooling system to confirm the core before teardown.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 4874045 heater core
      OEMCrown 4874045

      Replace a pressure-test-confirmed leaking or internally failed early-TJ heater core Fitment/availability: 1997-2001 Wrangler TJ with 2.5L or 4.0L and the compatible left-hand-drive HVAC box; not the 2002-2006 core. Confirm hose sizes and…

      Quadratec
    • Crown 5073180AA heater core
      OEMCrown 5073180AA

      Replace a pressure-test-confirmed leaking or internally failed late-TJ/LJ heater core Fitment/availability: 2002-2006 Wrangler TJ and Unlimited LJ, left-hand drive; not the 1997-2001 HVAC box and not right-hand drive.

      Quadratec
    • Zerex G05 HOAT yellow concentrate coolant
      OEMZerex ZXG051

      Refill the cooling system after core replacement only on the factory HOAT/MS-9769 branch Fitment/availability: Later TJ/LJ vehicles specified for Chrysler HOAT/G-05; verify the owner's manual/build and existing chemistry.

      AutoZone

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    Typical repair cost:$400 - $900

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler, the TJ/LJ Wrangler commonly develops coolant leaks from the plastic radiator end tanks, especially near the upper hose neck or crimp seam. Heat cycling and age make the plastic brittle, and owners often first notice a sweet smell, dried coolant residue, or overheating in traffic or on trails. This is one of the most frequently discussed age-related failures on 2000-2006 Wranglers.

    Common Symptoms

    • Coolant smell after driving
    • Visible coolant leak near radiator tank
    • Low coolant level
    • Engine running hot at idle
    • Dried white or orange residue on radiator

    How to Fix

    Pressure-test the cooling system and inspect the radiator tanks, seams, and hose necks for seepage or cracks. The standard repair is radiator replacement, usually along with fresh coolant, cap inspection, and replacement of aged hoses if needed. Many owners upgrade to a quality all-aluminum or heavy-duty replacement radiator for improved durability.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown Automotive 52080183 replacement radiator
      OEMCrown 52080183

      Replace a pressure-test-confirmed cracked or leaking radiator Fitment/availability: 2000-2006 Wrangler TJ/Unlimited 2.4L, 2.5L or 4.0L with manual or automatic transmission. Automatic applications use the integrated cooler fittings; veri…

      Quadratec
    • Crown Automotive 52079799AA 18 psi radiator cap
      OEMCrown 52079799AA

      Replace a cap that fails pressure/seal inspection during the radiator repair Fitment/availability: 2000-2006 Wrangler TJ/Unlimited 2.4L, 2.5L or 4.0L with an OE-style radiator neck; verify cap-to-neck engagement on any aftermarket radiator.

      Quadratec

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    Typical repair cost:$250 - $700

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    High Confidence

    On the 1997-2010 Jeep Wrangler, the solid-axle Dana 30 front end uses pressed-in upper and lower ball joints that wear out on high-mileage Wranglers, especially lifted rigs with larger tires. Worn ball joints introduce play in the steering knuckle, causing clunking over bumps, loose/wandering steering, uneven tire wear, and are a leading mechanical contributor to front-end vibration. A very high-demand maintenance search for older Wranglers.

    This issue also affects: Chrysler LeBaron

    Common Symptoms

    • Clunk from front end over bumps
    • Loose or wandering steering
    • Vibration through steering wheel
    • Uneven / cupped front tire wear
    • Play when rocking the tire top-to-bottom

    How to Fix

    Replace both upper and lower ball joints as a set once play is detected — Spicer/Dana 706944X, Crown RT21003 heavy-duty set, or Omix 18036.03 kit for TJ; JK uses its own Dana 30 set. Installation requires a ball-joint press (or knuckle off to a shop). Follow with a front-end alignment/toe set. Heavy-duty or rebuildable/greaseable joints are popular on wheeled rigs.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Dana Spicer 706944X upper/lower ball-joint kit, one side
      OEMDana Spicer 706944X

      Replace a measured-worn TJ upper and lower joint on one side Fitment/availability: 1997-2006 Wrangler TJ/LJ Dana 30/44 front axle; one kit services one side, so quantity two for both sides. Not for JK and not for a damaged/oversize axle …

      Quadratec
    • Dana Spicer 2007354 upper/lower ball-joint kit, one side
      OEMDana Spicer 2007354

      Not interchangeable with TJ 706944X.

      C&M Gearworks

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    Typical repair cost:$200 - $700

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    Medium ConfidenceVerifiedReviewed Jul 2026

    On the 2000-2006 Jeep Wrangler, tJ Wranglers commonly lose one or more cabin fan speeds because the blower motor resistor overheats or the connector melts. Owners usually notice the fan only works on high speed, or stops working on lower settings first. The issue is well documented in owner forums and service parts databases, especially on vehicles with aging blower motors that draw excess current.

    Common Symptoms

    • HVAC fan works only on high
    • One or more blower speeds inoperative
    • Burnt electrical smell from dash
    • Melted resistor connector
    • Intermittent cabin fan operation

    How to Fix

    Diagnosis is straightforward: verify which fan speeds work, inspect the resistor pack and harness for heat damage, and measure blower motor current draw. Replacing only the resistor may be temporary if the blower motor is dragging, so many repairs include both the resistor and pigtail connector. Cleaning cowl drains and checking for moisture intrusion can also help prevent repeat failures.

    What you need to fix it

    Only diagnosis- and fitment-reviewed repair parts are linked here.

    • Crown 4864957 blower-motor resistor
      OEMCrown 4864957

      Restore missing lower fan speeds after circuit testing confirms the early/RHD resistor is open Fitment/availability: 2000-2001 Wrangler TJ LHD or RHD, plus 2002-2006 TJ RHD.

      Quadratec
    • Crown 5139719AA blower-motor resistor
      OEMCrown 5139719AA

      Restore missing lower fan speeds after circuit testing confirms the redesigned LHD resistor is open Fitment/availability: 2002-2006 Wrangler TJ/Unlimited LHD branch; verify steering position and connector.

      Quadratec
    • Crown 5019941AA blower-resistor wiring repair harness
      OEMCrown 5019941AA

      Connector/harness repair when inspection finds heat damage, loosened terminals or melted plastic Fitment/availability: 1997-2006 Wrangler TJ/LJ application; use only when the connector is damaged and splice with the specified sealed meth…

      Quadratec
    • Crown 4864957K blower-motor resistor and wiring repair kit
      OEMCrown 4864957K

      Verify the supplied resistor geometry against LHD/RHD and model-year split before installatio

      Quadratec

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    Owner tips & cautions

    • TipIf the new resistor fails quickly, test blower motor amperage; a worn motor often overloads the resistor pack.
    • TipInspect the resistor connector for browning or melted plastic and replace the pigtail if any heat damage is present.
    Typical repair cost:$40 - $300

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    Community Reported
    High Confidence
    NHTSA Recalls20 recalls

    AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

    Chrysler (FCA US LLC) is recalling certain 2009-2013 Jeep Wrangler, Chrysler 300, Dodge Challenger and Dodge Charger vehicles, and 2009-2011 Dodge Dakota vehicles sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, Chrysler is recalling certain 2009-2010 RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Chrysler is also recalling certain 2009 RAM 3500, RAM 2500, RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, Dodge Durango, Chrysler Aspen, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles ever registered in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming. In the event of a crash necessitating deployment of the passenger frontal air bag, these passenger air bag inflator may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

    Campaign #18V02100009/01/2018

    AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

    Chrysler (FCA US LLC) is recalling certain model year 2007-2010 Jeep Wrangler JK vehicles manufactured March 2, 2006, to August 13, 2010. The clockspring assembly may become contaminated with dust and cause the air bag circuit to fail.

    Campaign #16V29000011/05/2016

    AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

    Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.

    Campaign #16V35200024/05/2016

    EQUIPMENT

    Quadratec, Inc. is recalling certain aftermarket accessory, driver-side, Ultimate Floor Liners part numbers 14254.0301 07, 14254.0301 08, 14254.0301Q, 14254.0302 07, 14254.0302 08, 14254.0302Q, 14254.0303 07, 14254.0303 08, 14254.0303Q, 14254.0309 07, 14254.0309 08, and 14254.0309Q sold from May 1, 2012, through February 14, 2013. The liners are for use in 2007-2013 Jeep Wranglers. The anchor point for the affected floor liners may tear during use, particularly when exposed to high temperatures. The tearing may allow the floor liner to shift forward.

    Campaign #13E01000025/02/2013

    AIR BAGS

    Chrysler Group LLC (Chrysler) is recalling certain model year 2008-2012 Jeep Wrangler right-hand drive vehicles manufactured February 1, 2007, through October 10, 2011. The affected vehicles have airbag clockspring assemblies that could experience broken airbag circuits.

    Campaign #13V17600007/05/2013

    + 15 more recalls. Check all on NHTSA.gov

    Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

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    Frequently Asked Questions

    What are the most common Jeep Wrangler problems?

    According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2000 Jeep Wrangler has 19 documented issues. The most frequently reported are: Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss, In-Tank Fuel Pump Module Failure — Whine, Hard Start & No-Start, 4.0L Crankshaft Position Sensor Thermal Failure — Random Stalling & Hot No-Start. Of these, 7 are rated critical and should be addressed promptly.

    Is the Jeep Wrangler reliable?

    The 2000 Jeep Wrangler has 19 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 7 issues are rated critical: Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss and In-Tank Fuel Pump Module Failure — Whine, Hard Start & No-Start and 4.0L Crankshaft Position Sensor Thermal Failure — Random Stalling & Hot No-Start and Front Frame Rust and Control Arm Bracket Corrosion and Body Tub, Floor Pan & Body-Mount Rust (Torque Box Corrosion) and Dana 35 Rear Axle Shaft C-Clip Failure ("Grenade") and 4.0L 0331 Cylinder Head Casting Cracking Between #3 and #4 Cylinders. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

    How much does it cost to fix common Jeep Wrangler problems?

    Repair costs for known Jeep Wrangler issues range from $20 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss, typically costs $250-$700 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

    What is the 2000-2006 Jeep Wrangler Clock Spring Failure Causing Airbag Light, Horn, and Cruise Control Loss?

    A common TJ/LJ Wrangler failure is the steering column clock spring wearing out internally, which breaks electrical continuity to the driver airbag, horn, and cruise-control switches. Owners typically report an illuminated airbag light along with an inoperative horn and cruise co… Repairs typically run $250-$700. Severity: high.

    What is the 1997-2006 Jeep Wrangler In-Tank Fuel Pump Module Failure — Whine, Hard Start & No-Start?

    The in-tank fuel pump module (pump, sending unit, and level float) wears out on high-mileage TJ Wranglers, producing a loud whine from the tank, hard starting, stalling, and eventual crank-no-start as fuel pressure drops. A top-searched TJ fuel-system failure, sometimes accompani… Repairs typically run $200-$550. Severity: high.

    What is the 1997-2006 Jeep Wrangler 4.0L Crankshaft Position Sensor Thermal Failure — Random Stalling & Hot No-Start?

    The crankshaft position sensor (CPS) on the 4.0L (and 2.5L) inline engines mounts on the transmission bellhousing and is exposed to severe heat soak. As it ages it develops intermittent thermal failure: the engine stalls without warning once hot, then refuses to restart until it… Repairs typically run $60-$250. Severity: high.

    What is the 2000-2006 Jeep Wrangler Front Frame Rust and Control Arm Bracket Corrosion?

    Rust-through of the TJ frame, especially near the lower control arm mounts, skid plate area, and rear trailing arm sections, is one of the most serious age-related Wrangler problems. In rust-belt states, owners report perforation severe enough to affect suspension mounting integr… Repairs typically run $800-$5,000. Severity: high.

    What is the 1994-2006 Jeep Wrangler Body Tub, Floor Pan & Body-Mount Rust (Torque Box Corrosion)?

    Distinct from frame corrosion, the steel body tub rusts from the inside out on older Wranglers, especially in salt regions. The spot-welded body-mount channels ('torque boxes') under the floor, the floor-pan seams, and the rocker areas trap moisture and rot around the three body… Repairs typically run $400-$3,500. Severity: high.

    What is the 1994-2006 Jeep Wrangler Dana 35 Rear Axle Shaft C-Clip Failure ("Grenade")?

    The Dana 35 rear axle fitted to most non-Rubicon YJ/TJ Wranglers uses a C-clip design: each semi-float axle shaft is retained inside the housing only by a C-clip seated in the differential. If a shaft snaps — common with 33-inch-plus tires, a locker, or aggressive trail use — the… Repairs typically run $300-$2,200. Severity: high.

    What is the 1999-2002 Jeep Wrangler 4.0L 0331 Cylinder Head Casting Cracking Between #3 and #4 Cylinders?

    The 4.0L inline-six heads carrying casting number 0331 (used on roughly 1999-2002 builds) were designed with enlarged intake/exhaust ports but left the deck wall between cylinders #3 and #4 too thin. Over high-mileage thermal cycling the head cracks in that area (visible through… Repairs typically run $1,200-$2,600. Severity: high.

    What is the 2000-2006 Jeep Wrangler Exhaust Manifold Cracking on 4.0L Inline-Six?

    A very common TJ Wrangler problem is cracking of the 4.0L exhaust manifold/header, especially around the collector and expansion joints. Repeated heat cycling and engine movement fatigue the factory manifold, leading to ticking noises on cold start, exhaust smell, and sometimes f… Repairs typically run $400-$1,200. Severity: medium.

    What is the 1997-2006 Jeep Wrangler Heater Core Leak — Coolant Smell & Fogged Windshield?

    The heater core inside the dash-mounted HVAC box develops leaks on high-mileage Wranglers, releasing a sweet coolant smell in the cabin, an oily film that fogs the windshield, and eventually a wet passenger-side carpet with unexplained coolant loss. A common older-Jeep HVAC searc… Repairs typically run $400-$900. Severity: medium.

    What is the 1997-2006 Jeep Wrangler Throttle Position Sensor (TPS) Failure — Erratic Idle, Stalling & Shift Problems?

    The throttle-body-mounted TPS wears and produces an erratic voltage signal, causing high/hunting idle, stalling at stops, hesitation or bucking on acceleration, and — on automatics — erratic or harsh shifting. A very common, high-search TJ driveability complaint that often illumi… Repairs typically run $50-$220. Severity: medium.

    What is the 2000-2006 Jeep Wrangler Radiator End Tank Cracking and Coolant Leaks?

    The TJ/LJ Wrangler commonly develops coolant leaks from the plastic radiator end tanks, especially near the upper hose neck or crimp seam. Heat cycling and age make the plastic brittle, and owners often first notice a sweet smell, dried coolant residue, or overheating in traffic… Repairs typically run $250-$700. Severity: medium.

    What is the 1997-2001 Jeep Wrangler 4.0L Oil Filter Adapter Housing O-Ring Leak?

    The 4.0 routes oil through a cast oil-filter adapter housing bolted to the block behind the filter, sealed by a set of rubber O-rings. The O-rings harden and shrink with age/heat, producing a persistent oil leak on the passenger side of the block that runs down the bellhousing an… Repairs typically run $40-$400. Severity: medium.

    What is the 1994-2006 Jeep Wrangler 4.0L Two-Piece Rear Main Seal Oil Leak?

    A leaking rear main seal is nearly universal on high-mileage 4.0 Wranglers — the two-piece crankshaft seal hardens and weeps oil at the back of the block, dripping onto the bellhousing and often collecting at the transmission. It is one of the most-searched 4.0 oil leaks and is f… Repairs typically run $200-$700. Severity: medium.

    What is the 1997-2010 Jeep Wrangler Dana 30 Front Ball Joint Wear — Clunking, Wandering & Steering Vibration?

    The solid-axle Dana 30 front end uses pressed-in upper and lower ball joints that wear out on high-mileage Wranglers, especially lifted rigs with larger tires. Worn ball joints introduce play in the steering knuckle, causing clunking over bumps, loose/wandering steering, uneven t… Repairs typically run $200-$700. Severity: medium.

    What is the 2000-2006 Jeep Wrangler Catalytic Converter Failure and Pre-Cat Efficiency Codes on 4.0L?

    TJ Wranglers with the 4.0L frequently develop catalytic converter deterioration, especially on higher-mileage vehicles and 2000-2006 emissions configurations using multiple converters/pre-cats. Owners commonly report a check-engine light with catalyst-efficiency codes, sulfur sme… Repairs typically run $600-$1,800. Severity: medium.

    What is the 2000-2006 Jeep Wrangler Ignition Coil Rail Failure Causing Misfire on 4.0L?

    The 4.0L coil-rail ignition system used on TJ Wranglers is known to develop internal failures that cause intermittent or persistent misfires. Owners report rough idle, hesitation, flashing check-engine lights, and cylinder-specific misfire codes, often after moisture intrusion, a… Repairs typically run $180-$500. Severity: medium.

    What is the 2000-2006 Jeep Wrangler Blower Motor Resistor and HVAC Fan Speed Failure?

    TJ Wranglers commonly lose one or more cabin fan speeds because the blower motor resistor overheats or the connector melts. Owners usually notice the fan only works on high speed, or stops working on lower settings first. The issue is well documented in owner forums and service p… Repairs typically run $40-$300. Severity: low.

    What is the 1994-2006 Jeep Wrangler 4.0L Valve Cover Gasket Oil Leak?

    One of the most common 4.0 oil leaks: the valve cover gasket hardens and seeps, typically worst at the rear of the head, leaving oil and grime down the back of the block and sometimes dripping onto the exhaust (burning-oil smell). Frequently mistaken for a more serious rear main… Repairs typically run $30-$300. Severity: low.

    What is the 1994-2006 Jeep Wrangler NP231 Transfer Case Rear Output Shaft Seal / Slip-Yoke Leak?

    The NP231 (Command-Trac) transfer case in YJ/TJ Wranglers uses a slip-yoke rear output. The rear output shaft seal is a chronic leak point — the exposed slip yoke picks up grit and rust that scores the seal, and a worn tail-housing bushing lets the yoke move and tear the seal. Re… Repairs typically run $20-$400. Severity: low.

    Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

    Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.