The 2002 Grand Cherokee WJ is mechanically stout but notorious for catastrophic transmission failures and 4.7L V8 head/bottom-end issues. When maintained religiously, the 4.0L I6 versions can exceed 200k miles, but neglect turns these into money pits fast.
45RFE/545RFE Transmission Failure with Cooler Contamination
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh 2-3 shift or slipping in 3rd/4th gear under load, Transmission fluid milky/pink from coolant cross-contamination, Delayed engagement when cold, then complete loss of forward gears, Metal shavings in pan during routine service
Fix: Cooler lines crack or internal radiator trans cooler fails, pumping coolant into trans and destroying clutch packs. Requires transmission rebuild or replacement plus external cooler install, radiator replacement if internal cooler failed, and full fluid system flush. 12-16 labor hours for trans R&R and rebuild.
Estimated cost: $2,800-4,200
4.7L V8 Cylinder Head Cracking and Valve Seat Failure
Occasional · high severity
Typical onset: 100,000-160,000 mi
Symptoms: Coolant loss with no visible leaks, white smoke at startup, Misfires on specific cylinders (usually 6 or 8) that don't clear with plug/coil swaps, Overheating episodes followed by rough idle, Bubbles in coolant reservoir when engine running
Fix: Early PowerTech heads prone to cracking between valve seats, especially rear cylinders. Requires both head gaskets, machining or replacement heads, timing components, and complete cooling system refresh. 18-22 labor hours. Many shops recommend shortblock if bearings show wear during teardown.
Estimated cost: $3,500-5,800
4.7L V8 Piston Slap and Rod Bearing Wear
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Cold-start piston slap that lasts 30-60 seconds (distinct hollow knock), Low oil pressure at hot idle below 20psi, Rod knock on acceleration after engine fully warmed, Metal glitter or chunks in oil filter during changes
Fix: Inadequate piston-to-wall clearance from factory and thin bearing design leads to premature wear. Piston slap alone can persist 50k+ miles, but rod bearing failure is sudden. Full rebuild with oversized pistons and upgraded bearings, or shortblock replacement. 20-26 labor hours.
Estimated cost: $4,200-6,500
4.0L I6 Cylinder Head Cracking (0331 Casting)
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: External coolant leak at back of head near firewall, Overheating with no visible radiator/hose leaks, Coolant smell in cabin, fogged windows, Cylinder 5 or 6 misfire with coolant in spark plug well
Fix: The 0331 casting (built 1999-2001, used through early 2002) cracks between cylinders 3-4 or near the coolant passages. Requires Tupy/newer 0331 replacement head or upgraded aftermarket casting, machining, and timing set. 10-13 labor hours. Verify casting number before purchase—Tupy castings rarely fail.
Estimated cost: $1,800-2,800
Front Lower Control Arm Bushing Failure
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking over bumps from front suspension, Steering wander and vague on-center feel, especially highway, Uneven inner tire wear on front tires, Visible torn rubber bushings at lower control arm pivot points
Fix: Factory rubber bushings deteriorate, causing alignment shift and poor handling. Replacement requires full lower control arms (bushings aren't serviceable separately in most shops). Alignment mandatory after. 3-4 labor hours both sides with alignment.
Estimated cost: $650-950
Transfer Case Chain Stretch and Viscous Coupler Failure (Quadra-Trac II)
Occasional · medium severity
Typical onset: 120,000-170,000 mi
Symptoms: Grinding or rattling from under vehicle during acceleration, Binding or jerking in tight turns on dry pavement, Service 4WD warning light intermittent or constant, Vibration at highway speeds that worsens under load
Fix: NV247 transfer case chain stretches, and viscous coupler lockup causes binding. Requires case disassembly, chain and coupler replacement, and new fluid. Many shops recommend reman unit swap for labor efficiency. 6-8 hours for rebuild, 4-5 for swap.
Estimated cost: $1,400-2,200
Fuel Pump and Sending Unit Failure
Common · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: Stalling or no-start when fuel tank below 1/4, Fuel gauge reading erratic or stuck at empty/full, Whining noise from rear during acceleration, Engine dies after 10-15 minutes running, restarts when cool
Fix: Fuel pump assembly fails from age and ethanol fuel degradation. Entire pump module with sending unit typically replaced as assembly. Tank drop required. 2.5-3 labor hours.
Estimated cost: $550-850
Owner tips
Change transmission fluid every 30k miles with Mopar ATF+4 ONLY—aftermarket fluids accelerate failure
Install an auxiliary transmission cooler immediately if towing or in hot climates
On 4.7L V8s, replace coolant every 2 years and verify thermostat operation—overheating episodes trigger head failures
For 4.0L I6, check cylinder head casting number (0331 vs Tupy)—walk away from 0331 unless already replaced
Inspect transmission cooler lines at radiator annually for cracks—$40 in lines prevents a $4k trans replacement
Buy a 4.0L I6 with Tupy head and service records; avoid 4.7L V8 unless you're comfortable with major engine work or budget $5k for preventive rebuild.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Chrysler (FCA US LLC) is recalling certain model year 2002-2003 Jeep Liberty vehicles manufactured January 9, 2001, to March 28, 2003, 2002-2004 Jeep Grand Cherokee vehicles manufactured February 13, 2001, to May 23 2003, and 2003-2004 Dodge Viper vehicles manufactured November 1, 2001, to June 30, 2004. Due to electrical noise beyond the tolerance of the air bag electronic control module (ECM), a component in the ECM may fail, causing the front air bags, side air bags, and/or seatbelt pretensioners to deploy inadvertently while the vehicle is being operated.
Consequence: Inadvertent deployment of the air bags may increase the risk of injury and the possibility of a vehicle crash.
Remedy: Chrysler dealers will replace the air bag control module and side impact sensors as required, free of charge. This recall remedy was applied during earlier recall campaigns of these vehicles under safety recalls 12V527 and 13V040. All owners that have not had the recall repair performed under safety recalls 12V527 or 13V040 are strongly encouraged to have it performed and not wait for the final remedy to be deployed to the field. The recall began on December 29, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R06.
AIR BAGS · 12V527000
2012-11-08 · EA12001
Chrysler is recalling certain model year 2002 and 2003 Jeep Liberty vehicles manufactured January 9, 2001, through March 28, 2003, and 2002 through 2004 Jeep Grand Cherokee vehicles manufactured February 13, 2001, through May 23, 2003. A component in the air bag control module may fail causing the front airbags, side curtain airbags, and/or seatbelt pretensioners to deploy inadvertently while the vehicle is being operated.
Consequence: Inadvertent deployment of the airbags may increase the risk of injury and the possibility of a vehicle crash.
Remedy: Chrysler will notify owners, and dealers will install a supplemental jumper harness to the airbag control module, free of charge. Owners were notified of the recall by interim letter in January 2013. The remedy for affected Liberty vehicles is expected to be available in April 2013. The remedy for affected Grand Cherokee vehicles is expected to be available later in the year. Owners may contact Chrysler at 1-800-247-9753.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
CHRYSLER IS RECALLING 103,409 MY 2001-2004 JEEP GRAND CHEROKEE VEHICLES WITH HEATED SEATS AND WITH CHRYSLER RECALL NO. 06V-197 COMPLETED (03-04 MY) OR SEAT HEATER ELEMENTS SERVICE REPLACEMENT (01-02 MY). THE FRONT SEAT ELECTRIC HEATER ELEMENTS COULD OVERHEAT.
Consequence: OVERHEATING COULD POTENTIALLY CAUSE A FIRE OR INJURY.
Remedy: DEALERS WILL REPLACE THE FRONT SEAT HEATER ELEMENTS FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 23, 2009. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.
EXTERIOR LIGHTING · 09E012000
2009-04-07
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
EXTERIOR LIGHTING · 06E064000
2006-07-17
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
Remedy: TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN · 06V199000
2006-06-08 · EA05020
ON CERTAIN SPORT UTILITY VEHICLES, THE PLASTIC BLADES OF THE ELECTRIC MOTOR DRIVEN COOLING FAN MAY SEPARATE AND PENETRATE THE SHROUD.
Consequence: IF THIS OCCURS WHILE THE HOOD IS OPEN, A PERSON IN THE VICINITY OF THE ENGINE COULD BE STRUCK BY THE BLADE AND INJURED.
Remedy: DEALERS WILL REPLACE THE ELECTRIC COOLING FAN MODULES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 4, 2006. OWNERS MAY CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
SERVICE BRAKES, HYDRAULIC · 06E022000
2006-03-13
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Consequence: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
EXTERIOR LIGHTING:HEADLIGHTS · 06E023000
2006-03-13
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
CERTAIN AFTERMARKET AIRTEX ELECTRIC FUEL PUMPS INSTALLED FOR USE AS REPLACEMENT EQUIPMENT FOR CERTAIN 1997-2004 JEEP WRANGLER; 1997-2001 JEEP CHEROKEE; 1997-2004 JEEP GRAND CHEROKEE; AND 2000-2003 DODGE DAKOTA VEHICLES. THE PLASTIC ELECTRICAL GROMMET CONNECTORS AT THE TOP OF THE FUEL PUMP MODULE ARE NOT COMPATIBLE WITH AUTOMOTIVE FUELS AND MAY DEGRADE CAUSING A POTENTIAL LEAK PATH FOR FUEL.
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FUEL LEAK COULD RESULT IN A FIRE.
Remedy: AIRTEX WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE AFFECTED FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 25, 2006. OWNERS MAY CONTACT AIRTEX CUSTOMER SERVICE DEPARTMENT AT 1-800-880-3056.
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH A 4.0L ENGINE ONLY, THE DESIGN OF THE INTAKE AND EXHAUST MANIFOLDS COULD ALLOW DEBRIS TO ACCUMULATE AT THE #3 CYLINDER LOCATION.
Consequence: THIS COULD RESULT IN A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL A MANIFOLD SHIELD TO MODIFY THE AIR FLOW CHARACTERISTICS AND TO PREVENT THE ACCUMULATION OF DEBRIS IN THE AREA OF THE #3 CYLINDER. OWNER NOTIFICATION BEGAN MAY 13, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
AIR BAGS:FRONTAL · 02V099000
2002-03-26
ON CERTAIN SPORT UTILITY VEHICLES, THE PASSENGER AIR BAG WIRING HARNESS WAS IMPROPERLY MANUFACTURED.
Consequence: THIS COULD CAUSE IMPROPER AIR BAG DEPLOYMENT IN CERTAIN CRASH CONDITIONS.
Remedy: DEALERS WILL ADD A WIRING JUMPER TO THE EXISTING CIRCUITRY TO CORRECT THIS CONDITION. OWNER NOTIFICATION BEGAN APRIL 29, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS · 02V032000
2002-01-31
CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH A FUEL TANK BRUSH GUARD FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 301, "FUEL SYSTEM INTEGRITY." THE ONBOARD REFUELING VAPOR RECOVERY (ORVR) CONTROL VALVE CAN BECOME DETACHED DURING A CRASH, ALLOWING FUEL LEAKAGE.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: DEALERS WILL EITHER REPLACE THE FUEL TANK BRUSH GUARD WITH A SKID PLATE OR REINFORCE THE EXISTING FUEL TANK BRUSH GUARD WITH A REINFORCEMENT BRACKET. OWNER NOTIFICATION WILL BEGIN MARCH 4, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
FUEL SYSTEM, GASOLINE:DELIVERY · 01V374000
2001-12-05
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE FUEL INLET CHECK VALVE COULD STICK IN THE PARTIALLY OPEN POSITION. THIS CONDITION COULD CAUSE FUEL TO SPILL OUT OF THE FILLER TUBE DURING REFUELING.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT THE FUEL INLET CHECK VALVE. VEHICLES FOUND TO HAVE A STICKING FUEL INLET CHECK VALVE WILL HAVE THE FUEL TANK ASSEMBLY REPLACED. OWNER NOTIFICATION BEGAN DECEMBER 24, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL · 01V348000
2001-11-13
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE ONBOARD VAPOR RECOVERY SYSTEM VENT HOSE MAY HAVE BEEN MISROUTED. THIS COULD ALLOW WATER TO ENTER THE CANISTER WHICH CAN CAUSE FUEL TO SPILL OUT OF THE FILLER TUBE WHEN REFUELING THE TANK.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT (AND REPOSITION AS NECESSARY) THE VENT HOSE. IF THE VENT HOSE IS FOUND IN THE BENT DOWN POSITION, AND THE VEHICLE HAS BEEN DRIVEN MORE THAN 20 MILES, THE CANISTER ASSEMBLY WILL BE REPLACED. OWNER NOTIFICATION BEGAN DECEMBER 3, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
VEHICLE DESCRIPTION: CERTAIN SPORT UTILITY VEHICLES ARE BEING RECALLED FOR A SOFTWARE ERROR IN THE INSTRUMENT CLUSTER MICROPROCESSOR. UNDER CERTAIN CONDITIONS, THE CLUSTER, WITH THE MAJORITY OF ITS GAUGES, ILLUMINATION, AND WARNING LAMPS, COULD BECOME INOPERATIVE.
Consequence: DRIVING THE VEHICLE WITH AN INOPERATIVE CLUSTER COULD CAUSE A DISTRACTION, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL RE-FLASH THE CLUSTER SOFTWARE TO CORRECT THE CONDITION. OWNER NOTIFICATION BEGAN OCTOBER 8, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
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