Problem Reports
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1994 Jeep Wrangler Problems
Various Engine Oil Leaks
Engine oil leaks from the valve cover gasket, oil pan gasket and timing cover gasket are common.
Ignition wires may fail and cause engine performance problems
Ignition wire failures can cause a rough idle or intermittent engine misfire and there might not be a Check Engine light.
Noise When AC is Tuned on Due to Incorrect Refrigerant Level
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).
Ticking Type Noise Due to Cracked Exhaust Manifold
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.
Front and Rear Differential Pinion Seal and Transfer Case Leaks
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.
Drivability Issues Due to Faulty Throttle Position Sensor
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.
Engine Performance Problems Due to Residue on Throttle Bodies
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.
Ticking Noise Due to Broken Exhaust Manifold Studs
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).
Dusty Conditions May Cause the Rear Main Oil Seal to Leak
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.
Revised speed sensor will solve internal leaks in sensor/adapter
Corroded tailgate hinges may make tailgate difficult to open
The tailgate hinges can corrode making it difficult to open the tailgate.
Brake pulsations due to warped front brake rotors
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).
Hood support rod may rattle
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