1994 Jeep Wrangler Problem Reports

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Ignition wire failures can cause a rough idle or intermittent engine misfire and there might not be a Check Engine light.

A hum or moan can be heard when the AC is turned on if the system is not charged with the correct amount of 134a refrigerant (.9 kPag or 32 oz).

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.

Leaks at the front and/or rear differential pinion seal and from the transfer case are common. Leakage from the transfer case normally occurs at the case-mating surfaces and require removal of the transfer case to reseal.

The throttle position sensor (TPS) may fail causing intermittent drivability problems like hard starting, stalling, and/or hesitation when accelerating. A failed TPS will require replacement, proper diagnoses should always be performed before replacing any parts.

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.

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).

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.

Internal leaks in the speed sensor or speed sensor gear adapter (speedometer adapter) are common. A revised speed sensor (white in color, old versions are black), used in production since November of 1993, solves the problem. If leaks develop between the sensor and the adapter or between the adapter and the transmission housing (transfer case if 4WD), a revised speedometer adapter is available.

The tailgate hinges can corrode making it difficult to open the tailgate.

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 hood support rod can rattle against the radiator driving over rough roads or when the doors are slammed. Installing a foam ring on the support rod can help to prevent the rattling.