Three problems related to steering tie rod assembly have been reported for the 2004 Jeep Wrangler. The most recently reported issues are listed below.
My 16 year old daughter was driving the vehicle on normal dry pavement when the casting that anchors the tie rod to the front left wheel snapped off. The vehicle violently pulled to the right causing it to go off the paved road surface and crashing into a tree. The vehicle has the original factory suspension and to my knowledge has never been modified.
A week after I purchased the vehicle I hit a small, sharp bump in the road and the vehicle front end began to shake and wobble uncontrollably. Only by slowing down to 45 mph was I able to gain control of the vehicle again. This has happened numerous times after this. I had the tires balanced, rotated and an alignment done on it. The wobble happened again, sometimes at even higher speeds and sometimes, not at all. I took it to an authorized Chrysler Jeep dealer and according to their recommendation, had a new steering stabilizer, new sway bar links and tie rod installed and again had the tires balanced and an alignment done on it. The vehicle still exhibits the same behavior. I have had it happen three times on interstate highways and lucky enough each time I was in the right lane and able to pull over onto the shoulder to reduce speed and gain control again. Each time on the interstate my speed was between 60 and 65 mph. The last time it happened I drove 20 miles back home on city streets in order to keep my speed below 50 mph. The "death wobble" does not happen below 50 mph although I can sometimes feel it starting to shake as I approach that speed. As I have had the vehicle inspected by an authorized Chrysler dealer, replaced the recommended parts and have done the required maintenance, I feel that there is a safety issue built into some of the vehicles like mine. I think this needs to be investigated as many Jeep Wrangler owners that I have talked to and authorized dealers also were very familiar with the term "death wobble" in conjunction with Jeep Wranglers. In fact, as I was describing the problem to one of the authorized Chrysler Jeep dealers, he interrupted me by saying, "ah, the "death wobble". Once it happens to you, you know that it is a very apt description of the behavior.
Vehicle will enter into a violent wobble and shake when hitting a bump at highway speed. Violent shaking does not stop until speed is reduced to under 20 mph. Had wheels rotated and balanced, wheels aligned. Checked all tie rods, ball joints, and linkage with no noticeable wear. Death wobble still present.