1991 Jeep Wrangler Problems
RepairPal has identified the most common problems with the 1991 Jeep Wrangler based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.
The outer exhaust manifold studs can break and cause exhaust leaks, commonly noted as a ticking type noise. The outer studs, clamps, and nuts will need to be replaced and are now being tightened to a reduced torque value (20 Nm/180 in lbs).
Loose or worn suspension and steering components can cause a wobble or shaking in the steering wheel. It may happen at a certain speed and subside as the vehicle accelerates through the range. Tire balance can contribute to this as well.
A ticking type noise may be noted from the engine area due to an exhaust manifold that has cracked where the pipes are welded; cracked manifolds should be replaced.
Some models are susceptible to rear main oil seal failures in dirty or dusty conditions. As dirt and dust collect on the oil seal, the abrasion wears through the sealing surface. A spacer is used between the bell housing and engine that has a small slot in the 12 o'clock position. Filling this slot with RTV silicone and cleaning the seal area can help prevent damage to the seal.
If the clutch is slipping when the clutch disc is 2/3 worn or if the clutch slave cylinder dust boot is torn, there may be insufficient clearance between the clutch slave cylinder and the clutch housing. A 5mm shim is available from Jeep that is installed between the slave cylinder and the clutch housing.
The throttle body may accumulate an oily, black residue in the bore and on the throttle plate causing hard starting or possibly stalling when coming to a stop. The throttle body should be cleaned during regular maintenance but do not spray cleaners directly on or at the throttle position sensor (TPS) as this can damage the sensor.
Due to warped front brake rotors or variations in the thickness of the rotors, brake pulsations may develop. The best method to reduce pulsations is to use an "On the Car" brake lathe (as long as the rotors are suitable for turning). "On the Car" equipment can correct variations (or "runout") in the rotor surfaces because it also corrects variations in other components (e.g. the hub).
The tailgate hinges can corrode making it difficult to open the tailgate.