Used KJ - Which year best for reliability? Auto/Manual?

Jeepin Pete · **Joined:** Wed Dec 12, 2012 5:08 pm **Posts:** 5

Hey all,
New guy here, but not a new jeeper. I come from the world of YJs, TJs, and WJs. My DD TJ has 233K on it, and rust is slowly consuming it. I need a new DD / camping / expedition rig, and I see a lot of low mileage (75K or so, to me) KJs in my area for a resonable price.

My research shows the 3.7 dropping valves, breaking valve springs, broken rocker arms....
Bad ball joints, tranny issues.... How unreliable are these things? :shock:

I put 215K on a WJ, 233K on my TJ, both with zero serious problems.

How about the manuals in the KJ? Is that a better choice than the auto? 5 speed or 6?

I like the idea of a KJ, and I'm not scared of mechanical things, but will I get a 75K mile KJ and have the motor self destruct when it drops a valve at 85K? :ALONE:

Is there a year that's best to look for? Was the 3.7 improved at any point to address any of the issues?
Thanks for any comments!

Pete

tjkj2002 · **Posted:** Thu Dec 13, 2012 1:00 pm

Well with the amount of 3.7's built your going to find some issues reported,really not that common when you look at how many total built(maybe over 20 million 3.7's) as it was used in alot of Chryslers,not just the KJ/KK.Balljoints are fixed by JBA's uppers and MOOG K3199 lowers.Lack of maintenance is the main cause of trans issues,granted the 42RLE is a little more prone to failure then the '02 KJ's 45RFE.

tommudd · **Posted:** Thu Dec 13, 2012 1:21 pm

Agree with tjkj and also how one was taken care of
example mine has over 179,000 right now, buddy has an 03 with over 210,000 neither have had any engine issues or transmission problems.
Both are well maintained though and I'd hop in mine and head out on a 3000 mile trip with only an oil change first.
So while you may hear of issues most all are due to maintenance in its lifetime or lack of it I'd say :2cents:

Jeepin Pete · **Joined:** Wed Dec 12, 2012 5:08 pm **Posts:** 5

Cool. Thanks a lot guys!

So there's really no 'bad' year or years to avoid, in the 2002-2007 range?

I like the look of the Limited.

I appreciate the help. Will probably start looking at them after the holidays. :JEEPIN:

Thanks again,
Pete

adamkrz · **Posted:** Sat Dec 15, 2012 10:14 pm

as far as the 5 speed manual trannys , Mine has 120k miles, both my kids learned how to drive standard with it and I tow a 3k camper and still on the same clutch.

The dealer replaced the valves on my KJ with about 40k on it due to constant misfire codes - Since then the Jeeps been perfect.

jeeptorino68 · **Posted:** Sun Dec 16, 2012 9:47 pm

i really like the 45RFE in my 02 defenitly a hefty transmission. though i would like to do some improvements to it in the future, it shifts like a car, even though it is a V8 trans...kinda soft.

some of the interior parts are a bit on the cheap/fragile side, but overall built with quality.
keep up on the maintenance and you will be fine. look for one that comes with records, or at least a long time owner.

mikey1273 · **Posted:** Mon Dec 17, 2012 12:18 am

I cant tell you about the 3.7 being a CRD owner but mine in over 3 years and 40,000 miles has been good. only trouble close to the engine for me has been the thermostat that failed open and is common with the crd. I have had no window regulator failures so far but had a sunroof drain tube clog up and leak on the carpet.

mine is a 5 speed auto that was only offered with the diesel and it seems sturdy. I tow a pop up with it and it pulls it nearly like its not there in tow.

off road i shocked the wrangler guys at Rausch creek with what i could do. they were very amazed a liberty could do near all the easy trails and some of the obstacles too. after the end of the bitter cold day they all wished they had a tight warm cabin and heated seats like my limited did

its a good jeep for a DD that will do some off road too with in its limits and your driving skill

Jeepin Pete · **Joined:** Wed Dec 12, 2012 5:08 pm **Posts:** 5

Guys, thanks so much. I have read up on the 45RFE vs the 42RLE, and I know about the April-03 changeover, and the crossmember differences as to spot one over the other.

I may search for the 6-speed manual also. My TJ has a 5-speed manual, and it's been awesome for 233K now......

Thanks again!! Still won't be until March-April that I purchase, I'll take the TJ through the winter, but I can't help checking out images of nicely built Expedition-style KJs. :CAMPING:

Pete

HustlinFlip · **Joined:** Mon Aug 22, 2011 9:16 pm **Posts:** 101

Don't quote me on this, but I believe I read somewhere that 02-03 KJ's with the 3.7L are more prone to sludge and broken rocker arms. I did some research about engine replacement for a 2003 Freedom KJ and realized 02-03 KJ's have a slightly different engine than my '04. Something to look into I guess. My '04 has just under 173k and the only problem I've had is having to replace the valve cover gaskets because of a small oil leak. But as the others have said, all depends on how well it was maintained or lack thereof when buying used.

Maccie · **Joined:** Fri Jun 15, 2012 4:52 am **Posts:** 18

Hi,

[Newbie warning]

This thing about the 45RFE transmission from '02 that is supposed to be sturdier than the 42 that came later - do you find the 45RFE in ALL '02 KJs no matter the specification?

Case in question: I have a '02 2.5 CRD (diesel) with the 5-speed manual gearbox - does it have the 45RFE?

Or are those only found in the petrol/automatic/whatever KJs?

Jeepin Pete · **Joined:** Wed Dec 12, 2012 5:08 pm **Posts:** 5

Cool - I can answer my first KJ question.... :mrgreen:

The 45RFE is an automatic transmission, so by default you do NOT have that, because you have a 5-speed manual.

Pete

mikey1273 · **Posted:** Mon Dec 17, 2012 6:50 pm

the 2.5L CRD was never sold in north America it was an export only model. and I think was only sold with the 5 speed manual NV1500 or more likely NV3500 for 2002 and 2003.
the CRD we did get in the states in 2005 and 2006 had the 2.8L engine and 5-45RFE 5 speed automatic transmission. the auto was the only transmission offered north America too.

the 2.8 also has a variable geometry turbo that did not make use of a waste-gate like the 2.5L engine did.

u2slow · **Joined:** Sun Mar 11, 2012 7:26 pm **Posts:** 160

The wife and I both like her 2005 6-speed. Comes with a stout NP241 t-case.

Main problem to watch for is difficulty with reverse. People screw up their 5-6 shift and catch reverse by accident while ripping down the highway - it bends the internal linkage, and it will pop out of reverse for ever after. Or rather, requires a heavy arm to keep it in there. I ended up buying a used trans from a wrecker with a guarantee. Changed the clutch at the same time. $1500 spent, and a couple days wrestling in the driveway. Oh well. Still glad its not an auto. :goink:

Used KJ - Which year best for reliability? Auto/Manual?

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