I know this is way late in the discussion. I've read through the posts and thought I would add some experiences I have had. I've been having the same issues for years and though I don't know what will fix the problem I have some ideas of what will not.
First lets start with what I have. I have two Jeeps, a 1998 Cherokee and a 2001 Wrangler. Both with the 4.0's, one with a distributor and one without. Both have had intermittent misfire problems.
I'll start with the Cherokee. It has had a problem since new and as a matter of fact is how I found
. When it was new all was well until I shut it off and then soon after restarted it. It would miss really bad and then after a short time go away. I had it at the dealer many times during the warranty period and they could never find a problem. Flash forward to today and the problem appears more often and is not induced only when the Jeep sits for a short time before a restart. Sometimes it happens when it is first started. In the past I have found plug wires jumping spark from the boots. I've replaced plug wires several times and recently with very expensive custom made sets. The problem doesn't go away. I've tried many types of spark plugs. Autolite, Bosch, AC, Champion truck plugs, NGK, Denso, etc, none help. It's funny, spark plugs are the one thing EVERYONE is positive is the problem. The conversation goes,
(friend) What plugs you runnin
(me) xxx brand
(friend) Oh, that's your problem, those don't work in there you need to run xyz
(me) Really, another guy told me those won't work and to try xxx
(friend) He's full of it, I've used xxx and it ran poorly, I switched to xyz and the problem went away
(me) what makes the xyz better
(friend) I have no idea but I know everyone I talk to has the same results
And so it goes, I try xyz to no avail. I'm going to say that IMHO spark plugs have one job to perform and any brand what so ever will do it, period. I'm not saying they are all equal and longevity will vary greatly, but they will all light the fire in the combustion chamber, especially when new. Get the correct type and heat range and they will do the job.
The 2000 is my wife's Jeep and as I said it has pretty much the same problem. Many times though if we replace the plugs the problem does go away for a short time but then reappears. I've never seen any sparking from the plug boots though. On hers I was told that I MUST run NGK's and from my experiences with dirt bikes I knew they worked pretty well, at least from a fouling perspective in a 2 stroke. I put the NGK's in and within 3000 miles we had a misfire in cyl 4 that wouldn't quit. So I bought some Autolites to replace them.
When I pulled them out and got to #4 I was shocked at what I found. The insulator for the electrode had split in half and was floating around in there. Luckily it didn't fall out of the cavity it was in because it could have destroyed cyl 4. Looking closely at the plug it was apparent that it cracked on a casting parting line. I've never seen a plug do this and I will not likley run NGK's again if I don't have to. I'm sure this failure was a fluke but the Jeep didn't run any better with them so why would I pay a premium for an imported plug when I can get US made plugs that work as well and I've never had a physical failure with.
On the 2000 I will note that ever since new plugs have degraded very rapidly. The first set I put in was at like 30,000 miles and they looked like they had 100,000 miles on them. I attribute this to three things, extremely high spark energy, very high combustion chamber temps (not engine temp), and intermittent preignition. I believe this motors are predisposed to detonation and preignition more than other motors. I believe the combination of high spark energy and high cc temps cause the early demise of plugs in these motors. I truly believe the factory should have used platinum plugs at the least in these motors or some other plug type that could deal with these conditions.
I think my '98 has much the same problem but the spark energy of the shared coil is a little lower. I do think the spark leakage from the plug wires is an indication of a still too much spark energy situation though. I'm thinking it is possible that when things are ideal with the plug wires (or the boots insulating properties) there may be cross firing inside of the distributor cap. When time permits I may drill some holes in the cap to watch and see what is going on in there. I've done this in the past on another vehicle and it cleared up a major problem I was having at high RPM. I may also just try running a lower energy coil. I did it once in an emergency but never considered running it like that for an extended period until now.
As I've said my situation at this point is not only relegated to when the motor has had time to heat soak. It happens more than not but not all of the time. I am currently running a 180* t-stat which did not help the misfire situation.
Soon I'm going to pull the 4.0's and drop in a couple of 5.0 V8's. That should solve the problem!
HTH,
B