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2004 Jeep Wrangler

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By Research the Car 6 min read

Here’s a breakdown of common issues and complaints for the 2004 Jeep Wrangler (TJ model), separated by category and engine/transmission configuration, following your requested format.

The 2004 Jeep Wrangler is a popular choice for off-road enthusiasts and those seeking a rugged, open-air driving experience. Engine options include the 2.4L inline-4 (147 hp, 165 lb-ft of torque) and the more common and desirable 4.0L inline-6 (190 hp, 235 lb-ft of torque). Transmission options include a 5-speed manual (NV3550 or AX-15, depending on engine) and a 4-speed automatic (42RLE). Owners appreciate the Wrangler’s off-road capability, simple design, and aftermarket support. Common dislikes include the on-road ride quality, wind noise, and fuel economy.

Body

  • Rust on the Undercarriage and Frame
    • Description/Symptoms: Rust can form in several areas on the frame, undercarriage, and rocker panels due to exposure to road salt, moisture, and off-road conditions. Excessive rust can lead to structural weakness and potential safety issues.
    • Solution: Rust repair or frame replacement is required. Cleaning and applying rust inhibitor is an effective prevention, as well as regular undercarriage washes.
    • Estimated Cost to Fix: $100 - $5,000+ (depending on severity, can range from minor repair to full frame replacement)
    • Recalls: None Found
  • Rust on the Windshield Frame
    • Description/Symptoms: Rust can form on the frame of the windshield, causing cosmetic issues
    • Solution: Rust repair or windshield frame replacement
    • Estimated Cost to Fix: $200 - $1,000+ (depending on severity and shop)
    • Recalls: None Found

Engine

4.0L Inline-6

  • Oil Leaks
    • Description/Symptoms: Common oil leaks from the rear main seal, valve cover gasket, and oil filter adapter. Visible oil drips, burning oil smell, and low oil levels are symptoms.
    • Solution: Replace the leaking seal or gasket.
    • Estimated Cost to Fix: $50 - $500 (depending on the leak location and labor)
    • Recalls: None Found
  • Cracked Exhaust Manifold
    • Description/Symptoms: A cracked exhaust manifold can cause a ticking noise, especially when the engine is cold. Also can cause reduced engine performance and fuel economy
    • Solution: Replace the exhaust manifold.
    • Estimated Cost to Fix: $300 - $600
    • Recalls: None Found
  • Overheating
    • Description/Symptoms: Coolant leaks from the radiator, hoses, or water pump can cause the engine to overheat. Also a clogged radiator or faulty thermostat can cause the engine to overheat. Visible coolant leaks, high engine temperature gauge readings, and steam from the engine bay are symptoms.
    • Solution: Replace the leaking component, flush the cooling system, or replace the thermostat.
    • Estimated Cost to Fix: $50 - $500 (depending on the component that is being replaced)
    • Recalls: None Found

2.4L Inline-4

  • Excessive Oil Consumption
    • Description/Symptoms: The 2.4L engine is known for consuming oil, especially at higher mileages. Symptoms include the need to frequently add oil, blue smoke from the exhaust, and potentially damaged catalytic converter.
    • Solution: Can try using high mileage oil or heavier weight oil, or replace piston rings/engine rebuild.
    • Estimated Cost to Fix: $20 - $3,000+ (Depending on what is being done)
    • Recalls: None Found
  • Timing Chain Issues
    • Description/Symptoms: The timing chain can stretch or wear, leading to poor engine performance, misfires, and potential engine damage.
    • Solution: Replace the timing chain, tensioner, and guides.
    • Estimated Cost to Fix: $500 - $1,000
    • Recalls: None Found

Transmission

42RLE 4-Speed Automatic

  • Transmission Slipping/Erratic Shifting
    • Description/Symptoms: The 42RLE transmission is known to have issues with the valve body and solenoids that can cause the transmission to slip, shift erratically, or fail to shift at all. Also sometimes a failed or damaged torque converter can cause issues.
    • Solution: Replace the valve body, solenoids, or torque converter.
    • Estimated Cost to Fix: $300 - $2,000+ (depending on the extent of the damage and the chosen repair)
    • Recalls: None Found
  • Overdrive Issues
    • Description/Symptoms: Some owners have reported issues with overdrive not engaging or disengaging properly, leading to poor fuel economy and increased engine RPMs at highway speeds.
    • Solution: Repair or replacement of overdrive clutch, solenoids, or transmission control module (TCM).
    • Estimated Cost to Fix: $200 - $1,500+
    • Recalls: None Found

NV3550 5-Speed Manual (Primarily with 4.0L)

  • Synchro Wear
    • Description/Symptoms: Difficult shifting into specific gears, especially 2nd or 3rd, grinding noises during shifting, and popping out of gear.
    • Solution: Transmission rebuild or replacement, including replacement of worn synchros and potentially other internal components.
    • Estimated Cost to Fix: $800 - $2,500+
    • Recalls: None Found

AX-15 5-Speed Manual (Primarily with 2.4L)

  • No Issues Found

Suspension

  • Death Wobble
    • Description/Symptoms: At highway speeds, the front end of the Jeep can start to shake violently, making it difficult to control the vehicle. This is often caused by worn ball joints, tie rod ends, track bar bushings, or a loose steering damper.
    • Solution: Replace worn suspension components and ensure proper alignment.
    • Estimated Cost to Fix: $100 - $1,000+ (depending on the components needing replacement)
    • Recalls: None Found
  • Worn Ball Joints
    • Description/Symptoms: Clunking noises from the front suspension, loose steering, and uneven tire wear.
    • Solution: Ball joint replacement.
    • Estimated Cost to Fix: $300-$800
    • Recalls: None Found
  • Worn Control Arm Bushings
    • Description/Symptoms: Clunking, rattling, or squeaking noises from the suspension. Vehicle may wander or feel loose on the road.
    • Solution: Replace control arm bushings or complete control arms.
    • Estimated Cost to Fix: $100-$600
    • Recalls: None Found

Electrical

  • Clock Spring Failure
    • Description/Symptoms: Loss of horn function, airbag warning light illumination, and potentially cruise control malfunction.
    • Solution: Replace the clock spring.
    • Estimated Cost to Fix: $200 - $400
    • Recalls: Yes - Recall # R03 (applies to certain 2007-2016 Wranglers, and 2008-2012 Liberties). If this recall applies to this vehicle, the repair is free.
  • Instrument Cluster Issues
    • Description/Symptoms: Gauges malfunctioning (speedometer, fuel gauge, etc.), erratic readings, or complete failure of the instrument cluster.
    • Solution: Repair or replacement of the instrument cluster. Sometimes can be repaired, if not replacement is required.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: The blower motor stops working, resulting in no air flow from the vents. This can be caused by a faulty blower motor resistor or a failing blower motor.
    • Solution: Replace the blower motor resistor or the blower motor.
    • Estimated Cost to Fix: $50 - $200+
    • Recalls: None Found

Summary:

The 2004 Jeep Wrangler, while iconic and capable, has its share of potential issues. Rust is a significant concern, especially in regions with harsh winters. Engine issues vary depending on the engine chosen, but oil leaks (4.0L) and oil consumption (2.4L) are common. The 42RLE automatic transmission can suffer from shifting problems. Suspension issues, particularly death wobble, require diligent maintenance and inspection of suspension components. Clock spring failures can also occur and may affect the vehicle’s safety systems. While some repairs are relatively inexpensive, others, like frame rust repair or transmission rebuilds, can be costly. Overall, a pre-purchase inspection by a qualified mechanic is highly recommended.

Jeep, Wrangler
Jeep Wrangler 2004
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