My company has three 06 KJs, two auto, one six speed. One of the autos with 72k on it died on the highway a few weeks ago. It would start and run, but only for about 30 seconds, then it died. Turned out that one of the cats was clogged. Warranty fixed that problem, but not the cause. The boss almost got the dealership to cover the valves, but ultimately got shot down. Unfortunately that means that we're no longer going to be buying jeeps for company vehicles
. Looks like we're going to be purchasing three brand new subarus in the next week or so
. I'd much rather pull up to a jobsite in a liberty than a subaru...but oh well.
As the mechanics explained it to me, the valve locks had been keeping the valves from rotating like they should, and so they wore unevenly. One cylinder only has about 100 psi of compression!! 3 out of the 6 cylinders have way lower compression than they should have. No one had reported any misfires or rough idles with this thing, but it is a company vehicle and lots of people drive it, most of which have no idea even how to put it in 4 wheel drive!! It's going to cost at least 4k to fix this problem. I'll update with cost details once the work is done. They'll be pulling both heads, having them checked (hopefully not replaced), have the valves re-seated, put in new valves, and valve locks (maybe springs too?). Not an easy job.
We bought these three vehicles brand new in 07, and now this one has been out of commission for a few weeks, and although we are going to fix it, it's going to be out for a few more. This really sux that DC doesn't cover this issue. It is 100% a manufacturing defect and not due to any improper use. My wife and I own three jeeps (well, before we were married I had two, she had one) and we've never had any issues. I beat the absolute doo doo out of both of mine...both XJs with 4.0L/AW4/231...I've posted pics in the past, one on 36" TSLs, detroits f/r, the other on 32" MTs and rear locker, etc. Hers is a stock liberty with skids and tow hooks....will get a small lift someday.
Anyone else with an 05-06 KJ, I would highly recommend either having the valve locks replaced NOW, or selling it before it's too late!!
Here's the TSB
http://home.comcast.net/~merchjo/jeep/jeeptsb-page-1.jpg
http://home.comcast.net/~merchjo/jeep/jeeptsb-page-2.jpg
Thank god my wife's KJ is an 04!!! 122k of abuse and still running great!! Knock on wood...
It's really too bad that we can't swap the 4.0L and AW4 into the liberty....