Kymasabe

I've heard here and there that 96 was the worst year to buy, the bastard year, the hardest year to find parts for, etc. I understand it was first year of OBD2 and went thru changes from previous year, but what are some of the challenges 96 owners face? I just read in another post that 96 uses a very specific fuel pump, i'd imagine ECM's and sensors are probably hard to find too but would like to know more/personal experience.
(Incidently, i own a 99, i ask purely out of curiousity).

robertj

It's not as big of a deal as some people make it out to be. The fuel pump assembly is a one off and available at many places including Amazon for under $200. It was actually the highest production year for the XJ ever, so there are a ton of parts in junk yards for them. Most parts from pre-96 fit them just fine. Sensors are no big deal either, and I've never needed to replace an ECM in my life. But if I did, I'm sure a salvage yard or eBay would be the best bet.

Sometimes you run into weird little things, like when I bought my carpet I had to buy carpet specified for a '97+ due to the hump where the front seats mount. A little Google-fu and I figured that out pretty easily and got the right part. Some guys complained in reviews that the carpet had to be modified if bought for a '96.

Other than that, I think they are the best year. ODB-II and the styling of the pre-97s. Not everyone's cup of tea, but I like it better. Also, you can get a lot better deal on a '96 then a '97+.

97+ XJs have electrical problems (no bus in the cluster), problems with the heads in the 2000 and 2001s, and honestly, I won't mess with them at this age. I had three 97+ XJs when they were newer, but now it's 96s and older for me.

00t444e

I wouldn't avoid a 96 model they aren't really that difficult to find pars for. I think that the 91-99 models where the best years. The main thing I look for is the chrysler 8.25 rear axle and not the dana 35.

Joshua White

Interesting to read about the 96 model year, I've heard that 97 is the problem child.

Kymasabe

....and its interesting to hear from other members what they consider "best" year or their favorite years. I've always thought 98 was the best year but may need to rethink that.

Bugout4x4

Thank you for the thread. I would be interested to hear more myself. Mine is a 97 but I think it was built in 96 so I would be curious if there are any "half year" issues with these years if any.

nickfancher1

Yeah they are a pain for some things. My mechanic replaced the output bearing on the transfercase, but one for a 96' wouldn't fit. Had to be for a 97.

I replaced the coolant temp sensor on the thermostat housing this summer. A 96' replacement is a different connector than what mine has. I had to get one for a 97'.

And my Jeep isn't a Frankenstein Jeep either!

wizardpc

Personal favorites are 99 for the new body style, 94 for the old----but I have learned that I need OBD2 in my life so I'd rather have a 99 than a 94.

Joshua White

Agreed just for the body style alone

Cane

some people will often say that 96 and 97 are years you don't want because some of the stuff is unique to those years, 96 being a cross over between old body style and OBDII change, and 97 for being the first year of a new body style, which you usually wanna stay away from. it also has some unique stuff to it, mainly the transmission I think.

but that being said, I own a 96 and it has never given me any major trouble. recently bad battery connections, and before that only the usual sensors that any year needs to have replaced anyway. some of the 96 sensors you need to get from a 97 that is true, but in my experience it has never caused me any troubles. I had to return a TPS to NAPA and got the 97 instead, same goes for the coolant temps sensor. I know the fuel pump is also unique for the 96, I already bought one and it's laying around somewhere ready to go in. A part from that, if the jeep itself is in good condition, it won't give you more trouble than another year, it's just about your personal taste. I feel that sometimes people will complain that jeeps are unreliable and never to buy one but the only reason is because they bought one that has been poorly maintained and/or thrashed in the trails, and they're stuck with a POS that always has issues no matter how much money you dump into it.

imo, with the 96 XJ you have the benefits of all the good stuff of both "generations" of XJs if I can call it that :

- 97+ changes like bigger axle shaft u-joints, chrysler 8.25 29 spline in the rear (the 3 '96 I know, including my own, all have 29 splines)
- 0630 head
- high pinion d30
- older body style which I prefer highly

and it's not even like I shopped around for the thing, it was just shoved in my face and I decided to buy it. looking back I think if I was offered a 97+ instead, being the kid I was not knowing a thing about XJs, I probably would not have bought it. the sole reason was the body style because it reminds me of 80s square style cars and I just love that.

are you sure it's output and not input? 95+ cases used a different input bearing. I bought a repair kit and had to be careful which one to order. 1995+ has the 16mm input bearing, while the years before had 24mm i believe. rockauto lists the same output bearing for the 96 and 97, which is why I'm wondering! I can check in my kit what the size is, just in case.

kyle96xj

My 96 also used a 97 ECT and my transfercase used the newer style shaft bearing, which made the SYE install easier, so I was thankful for that.

wizardpc

I used to be one of those people, honestly. Now that I have more experience I can say that's not a valid reason*. Why? Because every single year is has something unique to it. They made changes every year.

My 93 had a problem with the PCM. That's when I found out that 91-92 shared PCMs, and 94-95 shared PCMs, but 93 was it's own special thing.

I have a 98 now. I had a 99 for about 5 years. I was shocked to learn that the HVAC controls are completely different, as are the connectors for the rear hatch wiring. I pulled an overhead console out of a 97 (I think, maybe a 99) and the plugs for the wiring harness were the same but the pinouts were different. 99, btw, is the only year that has 3/4 length roof rails and a distributor. About 90% of the time I can tell you the exact year an XJ is just by looking at the body because of subtle changes in badging, moulding, and paint options.


*I know you're not saying it is. I'm not singling out anyone here. Just trying to spread knowledge in case it comes up in other discussions.

fb97xj1

The hardest part to find for the 96 is an original hardcopy of the FSM. You can download a copy from Pacificcoastmanuals, but i read somewhere that you will end up with a 97, not a 96. Most use the FSM for a 95. One of mine for the 97 (i think its the Body Diagnostics Manual) has additional pages. The original pages show connectors for a 96, but the pages taped on top of some show connectors that match my 97.

Whatever you go with, make sure its for an XJ. There were seperate manuals for the Grand.

Joshua White

This thread is already a wealth of knowledge...and I consider myself pretty damn knowledgeable about Jeep XJs.

Thanks for starting this Kymasabe :-)

Ralph77

My first XJ was a '96. Loved that Jeep. Ran like a champ. Never left me stranded. Problem with her was that structurally she was a disaster. Part of the uni-body was rotting away. Not to mention the floor pans. If I knew how to weld I would have saved her and would still own it. Instead I found an '00 Cheap. Pretty good body but had some mechanical issues. Mechanical I can deal with. For awhile I ran both Jeeps. The '96 would sit for months on end sometimes after I got the '00 up and running. Would go to start her and she would fire up every time. So I would not rule out '96's.