🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Product Type:

Workshop Service Repair Manual

👋 Introduction

Segment:

Compact SUV / Off-road vehicle

Reputation:

Iconic off-road capability, ruggedness, and open-air driving experience.

Competitors:

Toyota 4Runner, Land Rover Defender, Ford Bronco (early generations), Suzuki Samurai.

Design Philosophy:

Body-on-frame construction, solid front and rear axles, removable doors and roof, short wheelbase for off-road maneuverability.

Powertrain Options:

Renowned for its robust powertrain options suited for demanding conditions.

Target Audience:

Enthusiasts seeking off-road capability, adventure seekers, and those who appreciate classic Jeep styling.

📋 Manual Details

Applicable Years:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Estimated Pages:

Over 3000

Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, valve train, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, emissions control.

Transmission Drivetrain:

Manual transmission (AX-5, NV3550), Automatic transmission (30/42RH, 42RLE), transfer case (NP231J, NV241OR), axles (Dana 30 front, Dana 35C rear, Dana 44 rear), drivelines, differentials.

Brakes:

Front disc brakes, rear drum/disc brakes, parking brake system, hydraulic system, ABS (if equipped).

Suspension Steering:

Front coil spring suspension with solid axle, rear leaf spring suspension with solid axle, shock absorbers, control arms, steering linkage, power steering system, steering column.

Electrical Electronics:

Battery, charging system, starting system, lighting system, instrument cluster, dashboard controls, wiring diagrams for all circuits, fuses, relays, power windows, locks, mirrors, audio system.

Body Chassis:

Frame construction, body panels, doors, hood, tailgate, bumpers, interior trim, seats, convertible top system, hardtop installation/removal.

HVAC:

Air conditioning system, heating system, ventilation, blower motor, controls.

Fuel Emissions:

Fuel tank, fuel pump, fuel lines, fuel injectors, evaporative emission control system (EVAP).

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement, brake pad and rotor replacement, tire rotation, battery maintenance.

Diagnostics Troubleshooting:

Systematic diagnostic procedures for all major vehicle systems, troubleshooting guides for common issues, diagnostic trouble codes (DTCs).

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for engines, transmissions, axles, suspension, brakes, and electrical components.

Specifications Tolerances:

Torque specifications for all fasteners, engine specifications (bore, stroke, compression ratio), bearing clearances, valve lash, wheel alignment specifications.

Wiring Diagrams:

Comprehensive, full-color wiring diagrams for all electrical systems, including engine control, lighting, body electronics, and comfort systems.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostic procedures and detailed component specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for quick access to information.

Quality:

High-resolution, clear diagrams and text for easy readability.

Type:

N/A (Downloadable PDF)

Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Engine 1:

2.5L (150 cu in) AMC 150 Inline-4

Engine 2:

4.0L (242 cu in) AMC 242 Inline-6

4.0L Horsepower:

181 hp @ 4600 rpm (approx.)

4.0L Torque:

222 lb-ft @ 3200 rpm (approx.)

2.5L Horsepower:

117 hp @ 4500 rpm (approx.)

2.5L Torque:

135 lb-ft @ 3500 rpm (approx.)

Type:

Multi-point fuel injection (MPI)

ECM:

Chrysler's PCM (Powertrain Control Module) with diagnostic capabilities.

🔧 Transmission

Transmission 1:

5-speed Manual (AX-5 for 2.5L, NV3550 for 4.0L from 2000 onwards)

Transmission 2:

3-speed Automatic (30/42RH) for 2.5L, 4-speed Automatic (42RLE) for 4.0L from 2003 onwards

Transfer Case:

Command-Trac NV231J (standard), Rubicon's Rock-Trac NV241OR (optional)

Manual Fluid:

Mopar Manual Transmission Lubricant (or equivalent meeting API GL-3/GL-4, SAE 75W-90)

Automatic Fluid:

Mopar ATF+4 (or equivalent meeting Chrysler spec MS-9602)

📐 Dimensions

Wheelbase:

93.4 inches

Length:

151.3 inches

Width:

66.5 inches

Height:

70.5 inches (soft top)

Curb Weight Est:

3400 - 3800 lbs (depending on configuration)

Towing Capacity:

2000 lbs

Ground Clearance:

10.2 inches (approx.)

Approach Angle:

43 degrees

Departure Angle:

37 degrees

Breakover Angle:

26 degrees

🛡️ Safety Features

NHTSA Rollover:

3-star (typical for this era of SUVs)

ABS:

Available on most models, especially later years.

Airbags:

Driver and passenger front airbags.

Seatbelts:

3-point front and rear seat belts.

Frame:

Robust body-on-frame construction for durability and off-road resilience.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player (optional), cassette player (early models). Speaker configurations varied.

Navigation:

Not available from the factory during this period; aftermarket solutions are common.

Cruise Control:

Available on most models.

Aux Input:

Not standard; aftermarket solutions typically required for AUX/USB input.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendation).

Transmission Fluid Interval:

Automatic: 60,000-100,000 miles; Manual: Inspect periodically, change as needed or every 100,000 miles.

Coolant Interval:

Every 30,000-100,000 miles (depending on coolant type).

Engine Oil Spec:

SAE 10W-30 or 10W-40 for 4.0L, SAE 5W-30 or 10W-30 for 2.5L (API SN or newer recommended).

Coolant Spec:

Chrysler HOAT (Hybrid Organic Acid Technology) Extended Life Antifreeze/Coolant, typically orange (MS-9769).

Brake Fluid Spec:

DOT 3

Common Issues:

Cracking of the cylinder head on the 4.0L engine (especially earlier versions), heater core leaks, rust on the tub and frame, leaks in the cooling system, accessory drive belt noise, occasional death wobble (steering instability at speed, often due to worn components).

Tune Up Parts:

Spark plugs (NGK ZFR5N or equivalent), air filter (Mopar/Wix/Fram), oil filter (Mopar/Wix/Fram).

📚 Vehicle History

Jeep Legacy:

Direct descendant of the original Willys military Jeep, a symbol of ruggedness and off-road prowess.

Tj Introduction:

Introduced for the 1997 model year, replacing the YJ Wrangler. Marked a return to round headlights and coil springs for improved ride and articulation.

Tj Major Updates:

Significant updates included the introduction of the 4.0L inline-6 engine as standard on higher trims, improved interior comfort, and the Rubicon model with enhanced off-road hardware (Dana 44 axles, lockers, lower transfer case ratio).

Production Period:

1997-2006

Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Acclaim:

Consistently praised by off-road publications and enthusiasts for its capability and aftermarket support.

Value:

Often cited as a good value in the used market due to its durability and off-road potential.