96 XJ issues?

Newbie here, I have owned a few XJ's over the years but not for a long time. Looking at picking up a 1996 sport. From the photos I've seen its a 10 from 20 feet, but going to check in out tomorrow.
Just looking for some input of potential issue areas I should make sure I check out. Its a northeast Jeep so I'm sure it has some rust issues.

Thanks for the input.

The '96 is a bastard year with sometimes hard to figure out/find what parts you have/need, I personally wouldn't own one!

I've had a 96 for 13 years. It's always treated me fine. Never really had issues finding parts ... Idk where that would come from

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RCP Phx said:

The '96 is a bastard year with sometimes hard to figure out/find what parts you have/need, I personally wouldn't own one!

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SlowXj said:

I've had a 96 for 13 years. It's always treated me fine. Never really had issues finding parts ... Idk where that would come from

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I own a 1996 since the 2000. Years ago I had problems getting the correct parts at the discount parts store unless I took with me the old part. That is no loner the case. The reason being it is made up of parts from the earlier years XJ and the 1997 onward years. The dealer back then used the VIN and got me the correct parts every time.
For the amount of miles I have on it (over 380 000), I would say it is the most trouble free vehicle I have ever owned.

The only parts issue that comes to mind on my '96 was the CPS (for a spare). Don't let that year factor into your buying decision.

sdspearo said:

The only parts issue that comes to mind on my '96 was the CPS (for a spare). Don't let that year factor into your buying decision.

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Yes,.. including the distributor rotor. The power steering pump and mounting bracket are also for the later years but mounted to the old style log intake manifold.

I own a '96. Have had it since 2013. I have no complaints about it and would be happy to add another just like it to my stable.

Know that the fuel system is a one off design for '96. It has the steel tank of the earlier years, but runs a returnless fuel system like the later years. This means it has a unique sending unit/pump assembly in the tank. The tank itself is no different from the earlier years, but the sending unit/pump assembly with the built in fuel pressure regulator is unique to '96. That was a problem a few years back, but there are solutions should you need to service that particular component.

A couple other details worth knowing: '96 is the first year of OBDII for an XJ, meaning it is the only year of the early body style that is OBDII.

Also note that the airbag in a '96 (and '95) is a mechanically triggered airbag. It is "disconnected" via a bolt in the steering wheel itself. Back off the bolt and the airbag is deactivated.

At some point late in the '96 model year Chrysler switched over from 27 spline to 29 spline 8.25 rear ends. I do not know when that point was, but it was at least after April of '96.

I have nothing to complain about with my '96. I can drive it a thousand miles, go wheeling for several days and then drive it another thousand miles back home. In 2018 Wayne S. drove his '96 from the east coast to Moab, wheeled for the week, drove south to see more of the desert country and then drove back home. That trip was probably between four and five thousand miles.

I wouldn't worry about the year. I would be more concerned about rust, abuse and poor maintenance over the years.

Another one here with a 96 with over 300k. Saggy leaf springs, leaking power steering return line, and leaking radiator is all I had wrong with it. Got it with 290k and before me my brother in law used it as a work vehicle for over 10 years

My 1st XJ was a '96 & all I knew then was it it was "pre-facelift" as they were known here. Once I learned that there was no need to go to an American parts specialist (one major player supplied the wrong serpentine belt & didn't stock e-brake cables) AND discovered "Dorset Jeep" (thru' this very forum, I do believe) parts were never a problem, not that it ever required much, despite a 500 mile round trip every weekend for a year or so. Should've kept it but couldn't have known then that the money the subsequent '97 & '99 cost (on top of their purchase prices) would've been better spent on it. It's been sitting on the drive for, must be, 8 years now slowly donating parts - including PAS pump AND CPS - to the other 2 - & is still in better condition overall.

Another 1996 XJ owner here and once I'd discovered the idiosyncracies of this model year (complicated further by it being a RHD model which makes life interesting and means you belong to a very select club :wierd I am more than satisfied with my black XJ.


Thanks to the likes of Anak you can easily navigate these minor issues - his write up on the unique '96 fuel pump module in particular was invaluable.


As techno states - have the VIN to hand and any decent parts retailer will provide you with the correct part. I wouldn't trust online checkers however, although Rock Auto seem to have got it right.


Just make sure it's rust and crash damage free and starts & stops properly and you'll not regret it ..... oh yes, a m'ship helps :cheers:

..... oh yes, and do check the cooling system has been cared for - vital, or you'll spend many, many hours flushing it out and replacing temp. sensors, hoses, water pump, thermostat etc.. to get it up to scratch.

I never learned there was anything different about a '96 in the year or 2 it was my only "car" - but (a) it rarely needed anything (b) I didn't know any better.

As I've mentioned, much of it has become integrated with my 2 later models but if you want any parts (especially interior or panels), let me know.

danzy said:

Newbie here, I have owned a few XJ's over the years but not for a long time. Looking at picking up a 1996 sport. From the photos I've seen its a 10 from 20 feet, but going to check in out tomorrow.
Just looking for some input of potential issue areas I should make sure I check out. Its a northeast Jeep so I'm sure it has some rust issues.

Thanks for the input.

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Yeah, definitely crawl under an look for rust or a fresh undercoat to hide the rust.

I,ve driven my 96 to Moab twice,,,2008-4300+ and 2018-4500 + from Va and back.It used much gas,no oil and only a brake fluid top off. But be advised ...everything but the front D30 axle housing has been up-graded or replaced in the 445,000 miles I have owned it. Other than normal maintaince it has been mostly trouble free.Fuel pump(only the pump) have been replaced several times. Major rust repair was done before the 2018 trip.
It has been most dependable...would not hesitate to head back to Moab in it again.

I bought my 1996 Classic in 1997. I have now 215000 miles. Not all has been trouble free, but she still stands tall. Regardless of the make, it is getting more difficult to obtain oem parts for a 25 year old vehicle due to scheduled obsolescence by manufacturers. Aftermarket are hit and miss, and so are junk yards. To procure a 25 year old vehicle these are the common headaches you will have to endure. These forums are here to help along the way with ideas, fixes, suggestions and advice. Good luck...

From casual observation on visits I'd say there are more XJ's on the road than all their contemporaries put together, so keeping them going can't be that difficult. If we and the French, Spanish, Germans, Poles & Russians, in particular, can keep ours going, I'm sure you can. Long may that continue!

No crap! A few months back I saw an article about once popular cars that you don't see on the road anymore and they mentioned xjs! I have no idea what that guy was smoking but I see probably a dozen xjs on the road everyday, plus mine and I live in the middle of no where kansas. My town has 1200 people, our county has 7600 people in 400 Square miles and is full of old jeeps!

Perhaps it's because of where you are that you still see so many. In my experience, there tend to be more older vehicles in rural areas but on my travels in the US XJ's are still frequently seen (not that I've been for a couple of years now) - & most of those are DD's/working vehicles, not modified or obviously enthusiast owned/driven.

They are still popular and on the roads where I am. Lots of XJs and lots of 2nd gen Rams. I fit right in.

Good been to know things don't seem to have changed much in the couple of years I've not been allowed to visit (& the shopping list's got longer & longer).