Positioning:
The Jeep Wrangler TJ is an iconic, purpose-built off-road vehicle. This manual serves enthusiasts and professional mechanics working on this rugged and capable platform.
Competitors:
Competes with vehicles like the Ford Bronco (older models) and Toyota FJ Cruiser (later models) in the off-road utility segment, though the Wrangler's continuous production and dedicated fanbase set it apart.
Design:
Classic body-on-frame construction, solid front and rear axles, removable doors and top, exceptional ground clearance, and robust 4x4 systems define the TJ Wrangler.
Manual Value:
This comprehensive manual provides the technical expertise needed to maintain, diagnose, and repair the 2005 Jeep Wrangler TJ, ensuring its legendary capabilities are preserved.
Powertrain:
Engine (4.0L), Transmission (42RLE Automatic, NV3550 Manual), Transfer Case (NV241OR) diagnostics, repair, and overhaul.
Chassis:
Suspension (Solid Axles, Coil Springs), Steering (Power Steering System), Brakes (Front Disc, Rear Drum/Disc), Driveline (U-joints, Axle Shafts).
Electrical:
Wiring diagrams, ECU, sensors, actuators, lighting, power accessories, charging system, starting system.
Body And Frame:
Body panel removal/installation, convertible top service, frame inspection and repair, interior trim, HVAC system.
Maintenance:
Oil changes, filter replacements, fluid checks and flushes, tune-ups, lubrication.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), electrical system testing.
Repair:
Component removal, disassembly, inspection, assembly, and reinstallation for all major systems.
Specifications:
Torque specifications, clearances, measurements, fluid capacities, and resistance values.
Depth:
Comprehensive, covering everything from basic fluid checks and filter replacements to complete engine and transmission rebuilds, including detailed electrical diagnostics.
Quality:
High-resolution PDF, clear text, and legible diagrams.
Searchability:
Fully searchable text for quick access to specific information.
Printability:
Printable pages for on-the-job use.
Binding:
Digital (PDF) - No physical binding.
Paper:
N/A (Digital Format)
Engine Type:
4.0L Inline 6-Cylinder (242 c.i.d.)
Horsepower:
190 hp @ 4600 rpm
Torque:
235 lb-ft @ 3200 rpm
Fuel Delivery:
Multi-port Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Bore X Stroke:
3.875 in x 3.414 in (98.4 mm x 86.7 mm)
Firing Order:
1-5-3-6-2-4
Valvetrain:
Overhead Valve (OHV), 2 valves per cylinder, Hydraulic Valve Lifters
Transmission Type Std:
NV3550 5-Speed Manual
Transmission Type Opt:
42RLE 4-Speed Automatic
Clutch Type:
Hydraulically actuated single dry plate (Manual)
Transmission Fluid Manual:
Mopar Manual Transmission Lubricant or equivalent (API GL-3 or GL-4), 2.5 pints (2.37 L)
Transmission Fluid Automatic:
Mopar ATF+4 (MS-9602) or equivalent, 7.4 pints (7.0 L) pan fill
NHTSA Rollover Resistance:
4 out of 5 stars (for models equipped with side airbags)
ABS:
Anti-lock Braking System (ABS) standard on front wheels, available on rear.
Traction Control:
Optional traction control system available on some models.
Airbags:
Driver and passenger front airbags. Optional side airbags available.
Seat Belts:
Three-point seat belts with pretensioners.
Oil Change Interval:
Every 3,000 miles or 3 months, whichever comes first (severe service), or 6,000 miles / 6 months (normal service) with synthetic oil.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed. Replace at 30,000 miles for dusty conditions.
Transmission Fluid Change Auto:
Inspect every 30,000 miles, change at 60,000 miles or as needed (refer to manual for severe conditions).
Transmission Fluid Change Manual:
Check level periodically, change as recommended by manual or if contamination is suspected.
Engine Oil:
SAE 10W-30 (API SG or higher); Mopar 5W-30 Synthetic for cold climates (consult manual for full details).
Coolant:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) 50/50 mix with distilled water.
Power Steering Fluid:
ATF+4 (MS-9602)
Common Problems:
Leaking oil filter adapter housing, sway bar end link wear, transfer case chain stretch, minor electrical gremlins, rear main seal leaks on high-mileage engines.
Recommended Upgrades:
Many owners opt for upgraded steering components, robust skid plates, and improved suspension for enhanced off-road durability, all detailed in advanced sections of this manual.
Jeep Legacy:
Jeep's heritage dates back to World War II with the Willys MB, establishing a long-standing reputation for ruggedness and off-road capability.
Tj Generation:
The TJ Wrangler (1997-2006) introduced coil springs and a significantly revised suspension, moving away from the leaf springs of its predecessors (CJ and YJ), offering a superior ride and articulation.
Manufacturing Location:
Toledo, Ohio, USA
Production Years:
1997-2006 (TJ Generation)
Off Road Awards:
Consistently recognized by off-road enthusiasts and publications for its unmatched capability and customization potential.
Consumer Reports:
Varies by model year and specific components, but generally praised for off-road performance while noting potential reliability issues common in robust, off-road-focused vehicles.
Emissions:
Meets U.S. EPA and California Air Resources Board (CARB) emissions standards for its model year.
