🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Model Code:

TJ

Year:

2005

Product Type:

Parts Catalog

Chassis Code:

TJ

👋 Introduction

Market Position:

The 2005 Jeep Wrangler TJ represents the pinnacle of the iconic Jeep off-road experience. It is a segment-defining vehicle known for its ruggedness, go-anywhere capability, and distinctive open-air design. This parts catalog is essential for owners and mechanics seeking to maintain or restore these highly capable vehicles.

Competitive Analysis:

Competitors in the compact SUV/off-road segment for this era included vehicles like the Toyota Tacoma (4x4 variants), Nissan Xterra, and Land Rover Defender. The Wrangler TJ distinguished itself with its superior off-road geometry, solid front axle (a rarity), and unparalleled aftermarket support.

Key Features:

Iconic 7-slot grille, round headlights, removable doors and top, fold-down windshield, solid front axle (Dana 30), live rear axle (Dana 35 or Dana 44 in Rubicon models), commanding off-road visibility, legendary Jeep trail capability.

📋 Manual Details

Coverage Areas:

All major mechanical and body components, including engine, drivetrain, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, interior components, exterior body panels, and accessories.

Page Count:

Estimated 500+ pages (typical for comprehensive parts catalogs of this era)

Manual Type:

Illustrated Parts Catalog (IPC)

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered:

Engine assembly (short block, long block, cylinder head, valvetrain, oil system), Fuel System (tank, pump, lines, injectors), Cooling System (radiator, fan, water pump), Exhaust System (manifold, catalytic converter, mufflers), Drivetrain (transfer case, front axle, rear axle, driveshafts, U-joints), Transmission (manual, automatic), Clutch System (manual transmission), Braking System (front and rear brakes, master cylinder, calipers, lines), Steering System (gearbox, linkage, column), Suspension System (front and rear axles, control arms, springs, shock absorbers), Electrical System (wiring harnesses, fuse block, relays, ignition, starting, charging, lighting, instrumentation), Body (frame, chassis, body panels, doors, hood, tailgate, bumpers, interior trim, seats, HVAC, sound system, glass, mirrors).

Procedures Included:

Part identification and referencing, component diagrams with exploded views, part number lookup, assembly and disassembly sequence illustrations (for part placement), fastener identification and torque specifications (where applicable to component assembly).

Technical Depth:

Detailed and specific, focusing on the correct identification and sourcing of original equipment manufacturer (OEM) replacement parts. Provides visual representation of part relationships and assembly for accurate selection. Essential for accurate part ordering and ensuring vehicle originality and correct fitment.

Specific Part Groups:

Engine: Cylinder head assembly, pistons, connecting rods, crankshaft, camshaft, oil pump, water pump, radiator, fan shroud, heater core, exhaust manifolds, catalytic converter, mufflers. Drivetrain: Front axle assembly (knuckles, hubs, brakes, differential), rear axle assembly (Dana 35/44, differential, axleshafts, brakes), transfer case assembly, driveshafts, U-joints. Suspension: Control arms, track bars, springs, shock absorbers, sway bars, steering linkage, steering column, steering gearbox. Electrical: Starter, alternator, battery, ignition system components, lighting (headlights, taillights, turn signals), wiring harnesses, fuse box, relays, instrument cluster, switches. Body: Frame rails, crossmembers, body mounts, fenders, hood, doors, windshield frame, sport bar, bumpers, grille, tailgate, interior trim panels, seats, seat belts, dashboard, center console, soft top components, hardtop components, glass, mirrors. HVAC: Blower motor, evaporator, heater core, AC compressor, condenser. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors. Brakes: Master cylinder, brake booster, brake lines, front calipers, rear calipers, brake pads, brake rotors, parking brake assembly.

Troubleshooting Assistance:

While not a diagnostic manual, it aids troubleshooting by ensuring correct part identification and assembly, which are critical for resolving performance issues.

Upgrade And Modification Guidance:

Essential for identifying original components that may be replaced with aftermarket upgrades or for understanding the factory configuration before modification.

📊 Manual Specifications

File Format:

Portable Document Format (PDF), optimized for digital viewing and printing.

Print Quality:

High-resolution, enabling clear visibility of diagrams, part numbers, and text when printed.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Searchability:

Digital PDF format allows for text-based searching of part numbers, descriptions, and categories.

Diagram Quality:

High-quality exploded view diagrams clearly illustrating component relationships and assembly order.

Part Number Accuracy:

Provides official Mopar part numbers for accurate sourcing of OEM components.

⚙️ Engine Specifications

Primary Engine:

4.0L Inline-6 (PowerTech)

Engine Code:

ERH

Displacement:

3952 cc (241 cubic inches)

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Bore X Stroke:

3.878 in x 3.583 in (98.5 mm x 91.0 mm)

Compression Ratio:

8.7:1

Fuel System:

Multi-Port Fuel Injection (MPFI)

Engine Design:

Overhead Valve (OHV), cast iron block, aluminum cylinder head.

Oil Capacity:

5.0 US quarts (4.7 Liters) with filter

Oil Type:

SAE 10W-30 (API SJ or higher recommended)

Alternator Output:

130 Amp

Spark Plugs:

Champion Copper Plus (e.g., RC12LYC) or equivalent. Gap: 0.035 inches (0.89 mm).

🔧 Transmission

Standard:

6-speed manual (NV3550)

Optional:

4-speed automatic (42RLE)

Manual Transmission Fluid:

NV3550: SAE 75W-90 (API GL-4)

Automatic Transmission Fluid:

42RLE: ATF+4 (Mopar designation)

Transfer Case:

NV231 (Command-Trac) or NV241OR (Rubicon, Rock-Trac)

Transfer Case Fluid:

NV231/NV241OR: Mopar Manual Transmission Lubricant (MS-9224) or equivalent SAE 75W-80/75W-90 GL-4

📐 Dimensions

Exterior Wheelbase:

93.4 inches (2372 mm)

Exterior Length:

151.4 inches (3845 mm)

Exterior Width:

66.4 inches (1687 mm)

Exterior Height:

70.2 inches (1783 mm) (with soft top)

Interior Front Headroom:

42.2 inches (1072 mm)

Interior Rear Headroom:

40.2 inches (1021 mm)

Interior Front Legroom:

40.7 inches (1034 mm)

Interior Rear Legroom:

31.6 inches (803 mm)

Cargo Volume Behind Rear Seat:

44.5 cubic feet (1260 Liters)

Cargo Volume With Rear Seat Folded:

69.2 cubic feet (1960 Liters)

Curb Weight:

Approx. 3,500 - 3,800 lbs (1588 - 1724 kg)

Towing Capacity:

2000 lbs (907 kg)

Ground Clearance:

10.2 inches (259 mm) (Sport/Sahara), 12.9 inches (328 mm) (Rubicon)

🛡️ Safety Features

Ratings:

NHTSA: Frontal crash test ratings were typically 4 stars for driver and passenger. Side impact ratings varied, but generally good for the era. (Note: Specific ratings may vary by test year and configuration).

Active Features:

Four-wheel disc brakes (standard on most models), Anti-lock Braking System (ABS) (optional/standard depending on trim).

Passive Features:

Driver and front passenger airbags, three-point seat belts, energy-absorbing steering column, side-impact door beams, roll cage integrated into the windshield frame and sport bar.

💡 Technology Features

Infotainment:

Basic AM/FM/CD player, optional Infinity sound system with subwoofer, auxiliary input jacks were not standard. SiriusXM satellite radio compatibility could be added with aftermarket units.

Driver Assistance:

Limited by modern standards. Primarily focused on mechanical systems for off-road capability rather than electronic driver aids. ABS was an option.

Connectivity:

No built-in Bluetooth or USB ports as standard. Connectivity typically limited to the audio system's functionality.

🔧 Maintenance

Service Intervals:

Oil Change: Every 3,000-5,000 miles or 6 months. Tire Rotation: Every 5,000-7,500 miles. Air Filter: Inspect every oil change, replace as needed (or every 15,000-30,000 miles). Spark Plugs: Approximately 30,000-50,000 miles (depending on plug type). Coolant Flush: Every 30,000-50,000 miles or 2-3 years. Transmission Fluid: Automatic every 30,000-50,000 miles, Manual inspect annually, change as needed. Differential Fluid: Inspect every 15,000 miles, change every 30,000-50,000 miles.

Fluid Specifications:

Engine Oil: SAE 10W-30. Transmission Fluid (Auto): ATF+4. Transmission Fluid (Manual): SAE 75W-90 GL-4. Transfer Case Fluid: SAE 75W-80/75W-90 GL-4. Coolant: Mopar HOAT Antifreeze/Coolant (or equivalent ethylene glycol-based with organic acid technology, typically 50/50 mix with distilled water). Brake Fluid: DOT 3. Power Steering Fluid: ATF+4 (typically).

Known Issues:

Oil filter housing leaks (especially on 4.0L), exhaust manifold cracks, rear main seal leaks, transfer case chain stretch, axle seal leaks, steering box wear, common rust on body panels and frame (especially in certain climates), heater core issues, door hinge wear.

Recommended Filters:

Engine Oil Filter: Mopar MO-090 or equivalent (e.g., Wix 51515, Purolator L20097). Air Filter: Mopar P04547702 (or equivalent, e.g., Wix WA10077). Fuel Filter: Mopar 53030779 (inline type). Cabin Air Filter: N/A (pre-2007 Wranglers do not have cabin air filters).

📚 Vehicle History

Brand Heritage:

Jeep's lineage traces back to the original Willys MB military Jeep of World War II, establishing a global reputation for ruggedness, off-road prowess, and utility. This legacy is profoundly present in the TJ Wrangler.

Model Evolution:

The TJ Wrangler, produced from 1997 to 2006, marked a significant evolution from its YJ predecessor by reverting to round headlights and introducing a coil-spring suspension system (four-link suspension with track bars front and rear). This greatly improved ride comfort and articulation compared to the YJ's leaf springs.

Production Years:

1997-2006

Manufacturing Locations:

Toledo, Ohio, USA

Notable Trims Or Editions 2005:

SE, Sport, Sahara, Rubicon. The Rubicon variant featured Dana 44 axles, locking front and rear differentials, electronic sway bar disconnect, and a lower transfer case gear ratio for extreme off-road capability.

🏆 Awards & Recognition

Recognitions:

The Jeep Wrangler TJ consistently ranked high in off-road capability and consumer satisfaction for its segment. While specific awards for the 2005 model year may not be extensively documented, the TJ platform was widely praised for its iconic design and go-anywhere performance.

Ratings:

Consumer Reports and other automotive publications often rated the Wrangler highly for its off-road ability and durability, though less so for on-road comfort and refinement.

Certifications:

Not applicable in the context of awards; vehicle certifications pertained to safety standards (DOT, NHTSA).