Stiff Shift
Weak link: Double shifter boot
Models affected: '97-'99 TJ with manual transmission
What happens: These TJs use a lower and an upper shifter boot. The combined resistance of these two boots makes moving the shift lever difficult, especially in cold weather. The problem seems to manifest itself most when shifting from 1st to 2nd and 3rd to 4th gears. Burnsville Off Road says that they've seen transmission synchros get damaged because the transmissions are used with gears not fully engaged because of the resistance. Often, the stiff shifting is misdiagnosed as a faulty AX-15 transmission.
Strong fix: Some TJ owners remove the top shifter boot, which decreases the resistance and alleviates the problem, but it looks weird. The most popular method of freeing up the shifter is to make a small 1/8-inch cut in the lower boot, near the shift lever.
Contact: Burnsville Off Road, 952/890-3990, www.burnsvilleoffroad.com
Rattling Links
Weak link: Front antiroll-bar end links
Models affected: '97-'05 TJ
What happens: The antiroll-bar end links on these vehicles rate right up there reliability-wise with the Peugeot transmission and the 35C rear axle. They are a ball-and-socket type and they quickly wear out. Ours went out by 12,000 miles. The result is an aggravating rattling noise emanating from the front end of the vehicle as the ball bangs against the socket.
Strong fix: Don't bother replacing them with stock end links, because they'll wear out as well. A better idea is to install some aftermarket quick-disconnect end links. After all, they'll not only get rid of the rattle, but they'll also allow you to quickly disconnect the front antiroll bar to enhance front suspension travel off-highway. An example is Superlift's quick-disconnects that they say generate a much-appreciated 5 inches of additional wheel travel when disconnected.
Contact: Superlift Suspension Systems, 318/397-3000, www.superlift.com
Dead Knobs
Weak link: Climate control knobs
Models affected: '00-'02 TJ
What happens: The twist-style climate-control knobs were introduced in 2000, and they replaced the sliding-style controls previously used. These knobs are a unitized assembly and have a high failure rate. The folks at Burnsville Off Road tell us that they've replaced scores of these units. Problems generally revolve around unresponsive or partially unresponsive operation.
Strong fix: Sorry to break it to you, but like the failing seat cables, the only option is to purchase a new climate-control knob assembly from your local Jeep dealer. At least you now know why your knob isn't working.
Contact: Your local Jeep dealer
Broken Cable
Weak link: Seat pull straps
Models affected: '97-'99 TJ
What happens: Built in to the front of the seatbacks of the front seats are cables that allow you to tilt the seat forward to access the back seats without reaching behind the front seats to use the low-mounted lever. These cables have plastic ends that break, rendering the cable useless.
Strong fix: Unfortunately, when these cables break, the only option is to remove the seats and disassemble them to get to the broken cable. Even though this is a common problem on the '97-'99 TJ, parts can only be acquired through Jeep dealers, sorry.
Contact: Your local Jeep dealer
About This Series
This is the fifth installment of a series that will examine some of the common problems of popular four-wheel-drive vehicles and how to fix 'em. Past installments included Chevy fullsize trucks and SUVs (May '04), Ford fullsize trucks and SUVs (Aug. '04), Dodge fullsize trucks and SUVs (Apr. '05), and Toyota pickups and 4Runners (July '05). In future issues we're going to put the spotlight on other four-wheel-drive trucks and SUVs.