The 1994 Grand Cherokee ZJ was Jeep's first modern luxury SUV attempt, and while the 4.0L I6 is near-bulletproof, the AW4 automatic transmission and certain fuel system/electrical quirks define the ownership experience. Build quality was inconsistent in the early ZJ years.
AW4 Automatic Transmission Overheating & Failure
Common · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Slipping between gears, especially 3rd-4th under load, Burnt transmission fluid smell or dark/metallic fluid, Delayed engagement when shifting from park to drive, Check engine light with transmission-related codes
Fix: Factory transmission cooler is undersized; aftermarket auxiliary cooler is preventive must-do. Once slipping starts, rebuild or replacement needed. Rebuild: 12-16 hours labor. Used/reman unit swap: 8-10 hours.
Estimated cost: $1,800-3,200
Crankshaft Position Sensor Failure (4.0L I6)
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: No-start condition, cranks but won't fire, Stalling at operating temperature, restarts when cool, Intermittent dying while driving with no warning, No check engine light in many cases due to sudden loss of signal
Fix: Sensor mounted in bell housing, accessible from underneath. Common heat-soak failure. Replace sensor and pigtail connector (corrosion common). 1.5-2 hours labor. Always carry a spare—it'll strand you.
Estimated cost: $150-280
Fuel Pump & Tank Sending Unit Issues
Common · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: Fuel gauge reading empty when tank is full, or erratic bouncing, No-start or stumbling under acceleration when tank below 1/4, Whining noise from rear, especially during hot weather, Intermittent stalling that resolves after sitting
Fix: In-tank pump and sending unit corrode due to poor grounding and moisture intrusion. Must drop tank for access. Replace entire assembly, not just pump. 3-4 hours labor. Recall addressed some tank issues but not all failure modes.
Estimated cost: $450-750
Death Wobble from Worn Track Bar & Steering Components
Occasional · high severity
Typical onset: 70,000-130,000 mi
Symptoms: Violent steering wheel oscillation at 45-55 mph after hitting bump, Loose or vague steering feel on-center, Clunking from front end over bumps or during turns, Uneven tire wear on front tires
Fix: Track bar bushings wear, ball joints get sloppy, tie rod ends fail—all contribute. Requires systematic inspection of every steering/suspension joint. Typical fix: track bar, tie rod ends, and alignment. 4-6 hours labor for comprehensive refresh.
Estimated cost: $600-1,200
Heater Core Leaking (Coolant in Cabin)
Occasional · medium severity
Typical onset: 110,000-180,000 mi
Symptoms: Sweet coolant smell inside cabin, especially with heat on, Wet passenger-side floor mat or condensation on windshield, Overheating or low coolant level with no external leaks, Fogging windows that won't clear even with defrost
Fix: Heater core buried deep in dash—full dash removal required. This is a 10-14 hour job. Flush system and check hose connections first as they leak too. Many owners bypass the core to avoid teardown, losing heat but keeping vehicle drivable.
Estimated cost: $800-1,500
Rear Liftgate Glass Spontaneous Shattering
Occasional · low severity
Symptoms: Rear window explodes into small pieces without external impact, May occur parked in sun or after temperature changes, Often happens with no one near the vehicle
Fix: Factory defogger grid or frame stress causes tempered glass failure. Recall issued but many vehicles never fixed. Replacement glass: 1.5-2 hours labor. Aftermarket glass cheaper than OEM but verify defogger grid quality.
Estimated cost: $250-450
Vacuum Line Rot & HVAC Blend Door Issues
Common · low severity
Typical onset: 60,000-120,000 mi
Symptoms: Heat/AC vents defaulting to defrost only, regardless of dial position, No air from dash vents or floor vents, Hissing sound from under dash or engine bay, 4WD engagement issues (vacuum-operated transfer case switch)
Fix: Vacuum lines under hood become brittle and crack. Check valve at intake manifold fails. Tracing and replacing lines: 2-3 hours. Blend door itself rarely fails but actuator linkage can break—requires partial dash removal if so.
Estimated cost: $180-400
Owner tips
Install auxiliary transmission cooler immediately—cheapest insurance you can buy for the AW4
Keep spare crankshaft position sensor in glove box; it WILL fail eventually
Inspect and replace all vacuum lines proactively; they control more than you think
Avoid 5.2L V8 unless you need towing—4.0L I6 is far more reliable and easier to maintain
Service transfer case and differentials every 30k mi; they run hot and Chrysler fluids degrade fast
Buy a 4.0L I6 model with service records showing transmission cooler upgrade and recent front-end work—it'll run forever if heat and wobble demons are exorcised early.
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 Group LLC (Chrysler) is recalling certain model year 1993-1998 Jeep Grand Cherokee and 2002-2007 Jeep Liberty vehicles. The fuel tanks in these vehicles are at risk of failure and leakage in certain rear impacts.
Consequence: A fuel leak in the presence of an ignition source may result in a fire.
Remedy: Owners may take their vehicles to dealers and the dealers will perform a free inspection of the rear structure. On vehicles in the recall that are not equipped with a tow hitch, Chrysler will install a Chrysler designed tow hitch free of charge, provided the condition of the vehicle can support proper installation. On vehicles in the recall that are equipped with an aftermarket tow hitch, Chrysler will assess whether the hitch and surrounding areas show evidence of sharp edges or other puncture risks. If so, Chrysler will replace the tow hitch with a Chrysler designed tow hitch free of charge, provided the condition of the vehicle can support proper installation. On vehicles already equipped with a Chrysler designed tow hitch, Chrysler will inspect the area around the tow hitch installation, and if any installation issues are identified, they will be repaired free of charge. The recall began on August 1, 2014. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign numbers are N45 (for the Grand Cherokee vehicles) and N46 (for the Liberty vehicles).
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.
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.
VISIBILITY:GLASS, SIDE/REAR · 07E104000
2007-12-11
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
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.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:FLOOR SHIFT · 02V053000
2002-02-15 · EA01017
ON CERTAIN SPORT UTILITY VEHICLES, IF A DRIVER HAS NOT PLACED THE SHIFTER LEVER FULLY INTO THE "PARK" POSITION AND LEAVES THE VEHICLE RUNNING, THE VEHICLE MAY UNEXPECTEDLY MOVE REARWARD AFTER SEEMING TO BE STABLE.
Consequence: INADVERTENT MOVEMENT OF THE VEHICLE COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSTALL A SECONDARY DETENT SYSTEM TO THE FLOOR SHIFTER ASSEMBLY. DAIMLERCHRYSLER SENT INTERIM NOTICES TO OWNERS CONCERNING THIS PROBLEM ON MARCH 22, 2002. OWNER NOTIFICATION BEGAN SEPTEMBER 23, 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.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR · 99V340000
1999-12-13 · EA99014
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.
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