| Frame rust perforation | Salt exposure, trapped mud, poor undercoating | Cut/plate weld repairs; cavity wax; avoid rot | $1500-8000 |
| Body mount rot/crush | Rust at mount cups and captive nuts | Replace mounts; weld cups; align body | $800-3500 |
| Overheating under load | Clogged radiator, weak fan clutch, old hoses | New rad, fan clutch, hoses, thermostat, flush | $700-1800 |
| Head gasket failure | Chronic overheating, poor coolant maintenance | Head gasket, machine head, new bolts, cooling fix | $2500-6500 |
| Heater core leak | Corrosion from old coolant, electrolysis | Replace heater core; flush; check grounds | $900-2200 |
| Rear main seal leak | Age, crankcase pressure, worn seal surface | Seal replacement; check PCV/breather system | $900-2200 |
| Rocker cover gasket leak | Hardened gasket, over-torqued cover | Replace gaskets; clean breathers; reseal corners | $200-700 |
| Low oil pressure hot | Worn bearings, oil pump wear, sludge | Gauge verify; rebuild bottom end if confirmed | $3500-9000 |
| Turbo wear/smoke (diesel) | Poor oil changes, dusting, high EGT towing | Rebuild/replace turbo; fix intake leaks; EGT gauge | $1200-3500 |
| Injector wear (diesel) | Dirty fuel, high mileage, poor filtration | Test/replace injectors; new filter; clean tank | $1200-4500 |
| Injection pump leak/fail | Seal shrinkage, contaminated fuel, age | Reseal or rebuild pump; set timing correctly | $1200-4000 |
| Hard start when hot (diesel) | Pump wear, air leaks, weak starter/grounds | Fuel system leak test; pump service; cables | $300-2500 |
| EGR/intake clogging | Soot + oil mist buildup over time | Intake clean; EGR service; catch can where legal | $300-1200 |
| Dusting engine damage | Poor airbox seal, bad snorkel install, off-road | Fix sealing; compression test; rebuild if scored | $150-9000 |
| Auto trans slipping/flare | Overheating, old ATF, towing without cooler | Fluid service early; rebuild if slipping persists | $350-4500 |
| Auto trans overheating | Small cooler, towing, clogged radiator cooler | Add external cooler + temp gauge; flush system | $250-900 |
| Manual clutch wear | Heavy towing, big tires, off-road slipping | Clutch kit + flywheel machine; inspect rear seal | $900-2200 |
| Transfer case noise/leak | Low oil, worn bearings, seal aging | Reseal; rebuild bearings if noisy; correct oil | $300-2500 |
| 4WD hub/actuator failure | Vac leaks, seized hubs, neglected service | Replace lines/solenoids; rebuild hubs; test vacuum | $200-1200 |
| Diff lock won't engage | Actuator corrosion, wiring faults, low voltage | Clean/replace actuator; repair wiring; service diff | $300-1800 |
| Front wheel bearing failure | Water ingress, wrong preload, no grease service | Replace bearings/seals; set preload; repack | $350-1200 |
| Death wobble/shimmy | Worn bushes, bad caster after lift, loose bearings | Fix caster, replace bushes/ends; balance tires | $400-2500 |
| Steering box leak/play | Seal wear, sector shaft wear, big tires | Adjust if minor; rebuild/replace box; align | $400-1800 |
| Panhard/radius cracks | Hard off-road hits, rust, poor lift geometry | Weld/replace brackets; reinforce; correct geometry | $500-2500 |
| Brake hard line corrosion | Salt exposure, trapped mud on frame | Replace lines; flush fluid; inspect calipers | $600-2000 |
| Caliper seizure/uneven pads | Corrosion, neglected slide pins, old fluid | Rebuild/replace calipers; new pads/rotors; flush | $400-1400 |
| ABS sensor faults | Damaged wiring, rusted tone rings, mud | Repair wiring; replace sensor; clean tone ring | $150-700 |
| Charging/ground gremlins | Corroded grounds, weak alternator, bad mods | Voltage drop test; renew grounds; alternator rebuild | $150-900 |
| A/C weak or intermittent | Low refrigerant, compressor wear, blend door issues | Leak test/repair; recharge; replace compressor/actuator | $200-1800 |
| Cabin water leaks | Blocked drains, bad windshield seal, cowl rust | Clear drains; reseal glass; repair rust; dry carpets | $150-2500 |
| Exhaust manifold cracks/leaks | Heat cycling, broken studs, towing heat | Machine/replace manifold; new studs/nuts; check EGT | $400-1800 |
| DPF blockage (newer diesels) | Short trips, failed regen, bad sensors | Forced regen; replace sensors; DPF clean/replace | $300-3500 |
| Fuel contamination damage | Water/dirt in fuel, poor filtration, bad storage | Drain tank; replace filters; injector/pump service | $300-6000 |