2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Jeep Wrangler has 17 documented known issues, with 6 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) and Dana 35 Rear Axle Shaft C-Clip Failure ("Grenade") ($300-$2,200 repair). Across all issues with published estimates, repair costs range from $20 to $5,000. DIY maintenance guides at au7o.io.
POWER TRAIN:CLUTCH ASSEMBLY:PEDAL/HAND LEVER(MOTORCYCLE)
Chrysler (FCA US LLC) is recalling certain model year 2006 Dodge Viper and Jeep Wrangler and Liberty vehicles manufactured July 1, 2005, to July 31, 2006. In the affected vehicles, the springs within the clutch pedal position switch that prevents the vehicle from starting unless the clutch pedal is pushed down may break. As a result, the vehicle may not be started when the clutch pedal is pushed down or the engine may crank and start without the clutch pedal being pushed down causing the vehicle to unexpectedly lurch.
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.
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.
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.
AIR BAGS:FRONTAL
CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2008-2012 RIGHT HAND DRIVE (RHD) JEEP WRANGLER VEHICLES MANUFACTURED FROM FEBRUARY 1, 2007, THROUGH OCTOBER 10, 2011. SOME VEHICLES MAY BE EQUIPPED WITH DRIVER'S AIRBAG CLOCKSPRING ASSEMBLIES THAT COULD EXPERIENCE A COMPROMISED AIRBAG CIRCUIT RESULTING IN AN AIRBAG LAMP ILLUMINATION, WHICH INDICATES THAT THE AIRBAG MAY NOT DEPLOY.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Jeep Wrangler has 17 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, 6 are rated critical and should be addressed promptly.
The 2004 Jeep Wrangler has 17 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 6 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"). 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
