According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Jeep Grand Cherokee has 4 documented known issues, with 1 rated critical. The most serious is Rear-Mounted Fuel Tank Rupture and Fire Risk in Rear Impacts (Recall 13V-252 / Campaign N45) ($0-$0 repair). Across all issues with published estimates, repair costs range from $40 to $3,000. DIY maintenance guides at au7o.io.
On the 1994-2004 Jeep Grand Cherokee, for the ZJ (1993-1998) and WJ (1999-2004) Grand Cherokee, Chrysler mounted the plastic fuel tank behind the rear axle with little rear-structure protection. NHTSA and the Center for Auto Safety documented that these vehicles were far more likely to suffer a fatal post-crash fire in rear impacts. Recall 13V-252 (issued June 19, 2013) covered ~1.56 million 1993-2004 Grand Cherokee and 2002-2007 Liberty vehicles. This is one of the most-searched safety topics for older Grand Cherokees.
Common Symptoms
Fuel tank located behind the rear axle with minimal shielding
Elevated fire risk in rear-end collisions
Recall remedy (rear reinforcement hitch) not yet installed
How to Fix
Recall remedy (Campaign N45, free at Jeep dealers) installs a factory Mopar trailer-hitch/rear-structure reinforcement that shields the tank in low-to-moderate rear impacts. Owners should verify the recall was completed via VIN at NHTSA/the dealer; if not, have the hitch installed. Note critics consider the fix only a partial mitigation — the tank position is unchanged.
On the 1994-2004 Jeep Grand Cherokee, zJ (1993-1998) and especially WJ (1999-2004) Grand Cherokees in salt/rust-belt climates are notorious for corrosion of the rocker panels, rear quarter/wheel-arch lips, floor pans and rear cargo area. Because these are unibody structures, the rot is both cosmetic and structural, and it is a very common reason high-mileage examples fail inspection or get retired.
Common Symptoms
Bubbling paint and rust-through on rockers and rear wheel-arch lips
Perforated floor pans / water in cabin
Flaking rust in the rear cargo/spare-tire area
Structural weakness at jack points
How to Fix
Cut out corroded metal and weld in replacement panels: aftermarket rockers (Key Parts 0484-101 driver / 0484-102 passenger for 99-04 WJ) and rear wheel arches (Key Parts 0484-147), plus floor-pan sections as needed (Mill Supply / Classic 2 Current). Requires welding — professional bodywork recommended. Undercoat afterward and keep the rocker/pinchweld drain holes clear to slow recurrence.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Key Parts left outer rocker panel for 1999-2004 WJ
OEMKey Parts 0484-101
Left outer-skin component in a body-shop-confirmed repair with sound or separately repaired inner structure Fitment/availability: 0484-101 is the left/driver WJ panel and the live listing identifies 1999-2004 Grand Cherokee compatibility…
Key Parts right outer rocker panel for 1999-2004 WJ
OEMKey Parts 0484-102
Right outer-skin component in a body-shop-confirmed repair with sound or separately repaired inner structure Fitment/availability: 0484-102 is the right/passenger WJ panel and the live listing identifies 1999-2004 Grand Cherokee compatib…
Key Parts left outer rocker panel for 1993-1998 ZJ
OEMKey Parts 0483-101
Left outer-skin component in a body-shop-confirmed repair with sound or separately repaired inner structure Fitment/availability: 0483-101 is the left/driver ZJ panel and the live listing identifies 1993-1998 Grand Cherokee/Grand Wagonee…
Key Parts right outer rocker panel for 1993-1998 ZJ
OEMKey Parts 0483-102
Right outer-skin component in a body-shop-confirmed repair with sound or separately repaired inner structure Fitment/availability: 0483-102 is the right/passenger ZJ panel and the live listing identifies 1993-1998 Grand Cherokee/Grand Wa…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
WarningDo not place a jack or stand on a perforated or collapsing pinch weld. Have the lift points and adjacent structure assessed before the vehicle is raised there again.
WarningAn outer rocker panel is a repair skin, not proof that hidden inner structure is sound. Cutting and welding should follow a measured body-repair plan with fire protection and restored corrosion protection.
On the 1994-2004 Jeep Grand Cherokee 4.0L I6 (PowerTech 242), the 4.0L inline-six routes oil through an aluminum oil-filter adapter housing bolted to the block; its O-rings harden and leak with age, dripping oil down the rear/side of the block. Because the oil migrates rearward, it is very commonly misdiagnosed as a rear main seal or oil-pan leak. One of the most frequent 4.0L oil-leak searches for ZJ/WJ owners.
Common Symptoms
Oil leak/drip on the passenger side and rear of the block
Oil smell and spots under the vehicle
Oil on the oil filter and adapter area
Gradual oil-level drop with no smoke
How to Fix
Replace the oil-filter adapter O-ring kit — Crown Automotive / Mopar 4720363 (a 3-O-ring kit, adapter retained by a T60 Torx bolt). Clean the mating surface first. A popular permanent alternative deletes the adapter housing and runs a shorter PH3614-style filter directly. Confirm the source with the housing area cleaned and dye if needed before condemning the rear main.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
MAHLE oil-filter-adapter three-seal gasket kit
OEMMAHLE GS33781 / 72117 / 72119 / 72230
Seal replacement after the oil-filter adapter is confirmed as the first leak source on a 1994-2004 Grand Cherokee 4.0L Fitment/availability: GS33781 contains the three MAHLE seals mapped to the audited 4.0L endpoints.
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
TipDegrease the area and establish the first wet point before buying parts. Oil from the filter gasket, sender, valve-cover edge, oil-pan rail, or rear of the engine can cross the same area.
WarningThe old card's T60-fastener and adapter-delete advice was not universal enough for this full year span. Follow the service information for the exact adapter installed on the vehicle.
On the 1994-2004 Jeep Grand Cherokee, the HVAC blower-motor resistor on ZJ (1993-1998) and WJ (1999-2004) Grand Cherokees commonly burns out, leaving the fan working only on the highest setting (which bypasses the resistor). A worn blower motor drawing excess amperage cooks the resistor, and the connector often overheats. Very common, cheap, high-search fix.
Common Symptoms
Blower only runs on the highest (or a single) speed
No airflow on low/medium settings
Intermittent fan operation
Burnt smell or melted resistor connector
How to Fix
Replace the blower motor resistor located under the passenger-side dash — Mopar 5012699AA (RU-358) fits 1999-2004 WJ with ATC; use the matching resistor for manual A/C (Crown 4720278 for 93-99 ZJ/WJ manual). If a new resistor fails quickly, also replace the aging blower motor and the burnt resistor connector/pigtail to stop repeat failures.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Genuine Mopar manual-climate blower motor resistor for 1999 WJ
OEMMopar 4720278 / 04720278
Replacement after a 1999 WJ manual-climate circuit test confirms the resistor failed Fitment/availability: Mopar 4720278 is identified by the vehicle-specific catalog for the 1999 Grand Cherokee. Confirm VIN, manual controls, connector s…
Genuine Mopar manual-climate blower motor resistor for 2000-2004 WJ
OEMMopar 5014212AA
Replacement after a 2000-2004 WJ manual-climate circuit test confirms the resistor failed Fitment/availability: Mopar 5014212AA is cataloged for the audited 2000-2004 WJ manual-climate branch. Confirm VIN, HVAC type, connector shape, cur…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
WarningManual climate control and Automatic Zone Control do not use the same speed-control part. Confirm the HVAC control type before ordering.
TipInspect the connector for melting or loose terminals and check blower current draw; replacing only the resistor can fail again if the underlying circuit problem remains.
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.
Campaign #09V11700009/04/2009
SERVICE BRAKES, HYDRAULIC
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.
Campaign #06E02200013/03/2006
EXTERIOR LIGHTING
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.
Campaign #09E01200007/04/2009
EXTERIOR LIGHTING:HEADLIGHTS
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."
Campaign #06E02300013/03/2006
EXTERIOR LIGHTING:HEADLIGHTS
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.
What are the most common Jeep Grand Cherokee problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Jeep Grand Cherokee has 4 documented issues. The most frequently reported are: Rear-Mounted Fuel Tank Rupture and Fire Risk in Rear Impacts (Recall 13V-252 / Campaign N45), Body/Unibody Rust-Through — Rocker Panels, Rear Wheel Arches and Floor Pans, 4.0L Oil Filter Adapter Housing O-Ring Leak (Frequently Misdiagnosed as Rear Main Seal). Of these, 1 is rated critical and should be addressed promptly.
Is the Jeep Grand Cherokee reliable?
The 1996 Jeep Grand Cherokee has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Rear-Mounted Fuel Tank Rupture and Fire Risk in Rear Impacts (Recall 13V-252 / Campaign N45). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Jeep Grand Cherokee problems?
Repair costs for known Jeep Grand Cherokee issues range from $0 to $3,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Rear-Mounted Fuel Tank Rupture and Fire Risk in Rear Impacts (Recall 13V-252 / Campaign N45), typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 1994-2004 Jeep Grand Cherokee Rear-Mounted Fuel Tank Rupture and Fire Risk in Rear Impacts (Recall 13V-252 / Campaign N45)?
For the ZJ (1993-1998) and WJ (1999-2004) Grand Cherokee, Chrysler mounted the plastic fuel tank behind the rear axle with little rear-structure protection. NHTSA and the Center for Auto Safety documented that these vehicles were far more likely to suffer a fatal post-crash fire… Repairs typically run $0-$0. Severity: high.
What is the 1994-2004 Jeep Grand Cherokee Body/Unibody Rust-Through — Rocker Panels, Rear Wheel Arches and Floor Pans?
ZJ (1993-1998) and especially WJ (1999-2004) Grand Cherokees in salt/rust-belt climates are notorious for corrosion of the rocker panels, rear quarter/wheel-arch lips, floor pans and rear cargo area. Because these are unibody structures, the rot is both cosmetic and structural, a… Repairs typically run $500-$3,000. Severity: medium.
What is the 1994-2004 Jeep Grand Cherokee 4.0L Oil Filter Adapter Housing O-Ring Leak (Frequently Misdiagnosed as Rear Main Seal)?
The 4.0L inline-six routes oil through an aluminum oil-filter adapter housing bolted to the block; its O-rings harden and leak with age, dripping oil down the rear/side of the block. Because the oil migrates rearward, it is very commonly misdiagnosed as a rear main seal or oil-pa… Repairs typically run $100-$400. Severity: low.
What is the 1994-2004 Jeep Grand Cherokee Front Blower Motor Resistor Failure — HVAC Fan Works Only on High Speed?
The HVAC blower-motor resistor on ZJ (1993-1998) and WJ (1999-2004) Grand Cherokees commonly burns out, leaving the fan working only on the highest setting (which bypasses the resistor). A worn blower motor drawing excess amperage cooks the resistor, and the connector often overh… Repairs typically run $40-$250. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
