The 1991 Cherokee is a solid unibody SUV hampered by transmission cooler failures, cracked cylinder heads (especially 4.0L), and aging brake hydraulics. The 4.0L inline-six is generally bulletproof if you keep coolant clean and catch head cracks early.
Transmission Cooler Line & Radiator Failure
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Pink or milky fluid in transmission dipstick (coolant mixing with ATF), Transmission slipping or failure to engage after overheating, Coolant in transmission pan during service
Fix: Steel cooler lines rust through where they connect to the radiator, or internal radiator baffles fail, mixing coolant and ATF. Requires new radiator, both cooler lines, transmission fluid flush (sometimes full rebuild if contamination went unnoticed). 4-6 hours labor if caught early, 12-18 if transmission is damaged.
Symptoms: Overheating with no obvious external leaks, White smoke from exhaust, sweet smell, Coolant disappearing into combustion chambers, Rough idle or misfire on cylinders 3 or 4
Fix: The 0331 casting (1999-2001 but swapped into earlier trucks) cracks between cylinders 3 and 4. Requires head removal, replacement with Tupy 0630 or older 7120 casting, full gasket set, machining, coolant flush. 8-10 hours labor. Many '91s have had this repair already with a bad replacement head.
Estimated cost: $1,800-2,800
Rear Main Seal & Oil Pan Gasket Leaks
Common · medium severity
Typical onset: 120,000+ mi
Symptoms: Oil dripping from bell housing area onto ground, Oil coating transmission case and crossmember, Low oil level between changes
Fix: Both 2.5L and 4.0L engines develop leaks here due to age and heat cycling. Rear main requires transmission removal (4-5 hours labor); oil pan gasket is easier but still needs crossmember dropped. Often done together. Parts are cheap, labor is not.
Estimated cost: $600-1,100
Brake Master Cylinder & Hard Line Corrosion
Common · high severity
Typical onset: any mileage (age-related)
Symptoms: Spongy brake pedal that doesn't firm up after bleeding, Pedal slowly sinking to floor under sustained pressure, Visible rust perforation on steel brake lines along frame rails, Brake fluid leaking at master cylinder or along lines
Fix: Master cylinder internal seals fail, and steel brake lines rust through, especially in salt states. Recall addressed some lines but not all. Full brake line replacement (all four corners) takes 6-8 hours. Master cylinder alone is 2 hours. Do not defer this.
Estimated cost: $400-700 (master only); $1,200-2,000 (full line replacement)
AW4 Transmission Slow Reverse Engagement (4.0L)
Occasional · medium severity
Typical onset: 150,000+ mi
Symptoms: 2-3 second delay engaging reverse when cold, Harsh or delayed 1-2 shift, No reverse at all after sitting overnight
Fix: Rear servo seals harden and leak, causing weak reverse pressure. Also check valve body and governor pressure sensor. Fluid and filter change sometimes helps temporarily. Full rebuild addresses it permanently. 8-10 hours labor for rebuild.
Estimated cost: $1,800-2,800 (rebuild)
Crankshaft Position Sensor Failure (4.0L)
Occasional · high severity
Typical onset: any mileage (heat-related)
Symptoms: No-start when hot, restarts after cooling 20-30 minutes, Intermittent stalling at idle or while driving, Check engine light with P0320 or no codes at all
Fix: Sensor mounted in bell housing fails from heat soak. Easy replacement (1 hour) but requires crawling under vehicle and working around transmission. Carry a spare if you off-road.
Estimated cost: $150-250
Vacuum Line Dry-Rot and 4WD Engagement Issues
Occasional · low severity
Typical onset: any mileage (age-related)
Symptoms: 4WD won't engage or disengages randomly, Hissing sound under hood, Rough idle or high idle fluctuation
Fix: Vacuum lines feeding the transfer case shift motor crack and leak. Also affects HVAC blend doors. Replace all vacuum lines as a set (2-3 hours). Check the axle disconnect on passenger side as well; it seizes or the fork breaks.
Estimated cost: $200-400
Owner tips
Replace transmission cooler lines and radiator preventively at 100k miles—cheap insurance against $3k repair
Flush coolant every 30k miles with distilled water mix to延 slow head cracking
Inspect brake lines annually if you're in the rust belt; budget for full replacement
The 4.0L is near-bulletproof if you stay ahead of cooling system maintenance—don't let it overheat even once
Buy the 4.0L version if the head's been replaced with a good casting and the trans cooler is recent—otherwise budget $3k-5k for deferred maintenance catching up with you.
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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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.
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 · 06E026000
2006-03-23
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS 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 WITHOUT WARNING.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR · 98V005000
1998-01-12 · RQ98023
VEHICLE DESCRIPTION: PASSENGER AND MULTI-PURPOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, ILLINOIS, INDIANA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, OR WISCONSIN, AND THE DISTRICT OF COLUMBIA. THE FRONT DISC BRAKE ROTORS CAN EXPERIENCE SEVERE CORROSION IF OPERATED FOR AN EXTENSIVE PERIOD IN THE "SALT BELT." IF THE ROTORS ARE NOT REPLACED, THE CORROSION CAN EVENTUALLY COMPROMISE THE STRUCTURAL INTEGRITY OF THE STAMPED STEEL CENTER HUB SECTION OF THE ROTOR.
Consequence: THE REDUCED STRENGTH CAN ALLOW THE CAST IRON WEAR SURFACE TO SEPARATE FROM THE HUB, REDUCING THE BRAKE EFFECTIVENESS OF THE VEHICLE.
Remedy: DEALERS WILL REPLACE THESE ROTORS WITH ROTORS THAT ARE COATED WITH A CORROSION PROTECTION.
VEHICLE DESCRIPTION: MULTIPURPOSE PASSENGER VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. DRIVERS CAN MISTAKENLY STEP ON THE ACCELERATOR PEDAL WHEN THEY INTEND TO STEP ON THE BRAKE PEDAL.
Consequence: PEDAL MISAPPLICATION BY A DRIVER CAN CAUSE UNINTENDED ACCELERATION.
Remedy: DEALERS WILL INSTALL A SHIFT INTERLOCK ON THE AUTOMATIC TRANSMISSION OF THESE VEHICLES.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP · 96V260000
1996-12-27
VEHICLE DESCRIPTION: VEHICLES EQUIPPED WITH ANTILOCK BRAKE SYSTEM (ABS).
THE ANTILOCK BRAKE SYSTEM (ABS) HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR WHICH COULD CAUSE PUMP-MOTOR DETERIORATION.
Consequence: IF THIS OCCURS, THE ABS FUNCTION WOULD BE LOSE AND REDUCED POWER ASSIST WOULD BE EXPERIENCED DURING VEHICLE BRAKING. THE INSTRUMENT PANEL WARNING LIGHTS WILL SIGNAL SYSTEM IMPAIRMENT AND THE BASE MANUAL BRAKES WILL REMAIN FUNCTIONAL.
Remedy: DEALERS WILL TEST THE VEHICLE'S ABS AND REPAIR AS NECESSARY. THE WARRANTY ON ALL ABS COMPONENTS WILL BE EXTENDED TO 10 YEARS OR 100,000 MILES (EXCEPT FOR THE BRAKE ACTUATOR PISTON ASSEMBLY AND THE PUMP-MOTOR ASSEMBLY WHICH WILL HAVE A LIFETIME COVERAGE). OWNERS WILL BE REIMBURSED FOR PREVIOUS ABS COMPONENT REPAIR COSTS.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 91V063000
1991-04-15
IMPROPER INSERTION/CRIMPING OF THE HOSE-TO-END FITTINGS OF THE HIGH PRESSURE HOSE ON THE ANTI-LOCK BRAKE SYSTEM CAN CAUSE DETACHMENT OF THE HOSE FROM THE ABS SYSTEM, AND DISCHARGE OF HYDRAULIC FLUID.
Consequence: DETACHMENT OF THE HOSE FROM THE ABS SYSTEM CAUSES THELOSS OF THE ABS FUNCTION AND HYDRAULIC BRAKE ASSIST, LEAVING ONLY MANUAL BRAKESAND DECREASING STOPPING ABILITY, WHICH COULD RESULT IN AN ACCIDENT. DISCHARGE OFHYDRAULIC FLUID IN THE AREA OF THE HOT EXHAUST SYSTEM COULD RESULT IN AN ENGINECOMPARTMENT FIRE.
Remedy: REPLACE THE ABS HIGH PRESSURE HOSE.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 91V023000
1991-02-11
IMPROPERLY INSTALLED BRAKE FLUID TUBE MAY ALLOW THE TUBE TO CONTACT THE STEERING INTERMEDIATE SHAFT DAMAGING THE TUBE.
Consequence: BRAKE FLUID LEAKAGE COULD OCCUR AND RESULT IN PARTIALLOSS OF BRAKING CAPABILITY.
Remedy: REPOSITION BRAKE TUBE TO AVOID CONTACT WITH STEERING SHAFT; ALSO, REPLACE ANY DAMAGED BRAKE TUBES.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 90V206000
1990-12-18
SUSPENSION JOUNCE BUMPER COULD CONTACT LEFT REAR WHEEL BRAKE TUBE WHEN SUSPENSION IS AT FULL JOUNCE (BOUNCE).
Consequence: CONTACT AT FULL JOUNCE MAY CAUSE THE BRAKE TUBE TOCOLLAPSE AND RESTRICT THE HYDRAULIC BRAKE FLUID PRESSURE TO THE LEFT REAR BRAKEWHICH AFFECTS THE BRAKING CAPABILITY OF THE VEHICLE.
Remedy: REPLACE LEFT REAR BRAKE TUBE WITH TUBE DESIGNED TO ELIMINATE CONTACT WITH BUMPER.
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