🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Platform Code:

TJ

👋 Introduction

Segment:

Compact SUV / Off-Road Vehicle

Competitors 2004:

Toyota Tacoma (though often compared to smaller SUVs), Suzuki Samurai (historically), Hummer H3 (later), Land Rover Defender (in off-road capability focus)

Jeep Legacy:

Continues the Jeep legacy of ruggedness, off-road capability, and iconic styling.

Design Philosophy:

Body-on-frame construction, solid front and rear axles (on some models, but TJ has specific configurations), removable doors and roof contribute to its unique appeal.

Purpose:

Essential tool for maintaining, diagnosing, and repairing the Jeep Wrangler TJ, ensuring longevity and optimal performance. Inexpensive way to keep the vehicle working properly.

📋 Manual Details

Engine Systems:

Yes

Transmission Systems:

Yes

Chassis Systems:

Yes

Electrical Systems:

Yes

Body And Interior:

Yes

Climate Control:

Yes

Restraint Systems:

Yes

Estimated Pages:

2000+

Type:

Factory Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete rebuild, diagnostics, specific component servicing (e.g., Cylinder Head, Cylinder Block Assy, Camshaft, Crankshaft, Oil Pump, Water Pump)

Engine Control System:

SFI System, Emission Control Systems, Knock Sensor, Camshaft Position Sensor, Throttle Body Assy, Fuel Injector diagnostics and servicing

Cooling System:

Radiator Assy, Thermostat, Water Pump Assy, Cooling Fan System, Engine Coolant specifications and replacement

Fuel System:

Fuel Tank, Fuel Pump, Fuel Injector servicing, Fuel System diagnostics

Ignition System:

Spark plug replacement, ignition coil diagnostics, related wiring

Exhaust System:

Exhaust Pipe, Exhaust Manifold, Catalytic Converter servicing and replacement

Transmission Manual:

Manual Transaxle Assy, Manual Transaxle Oil specifications, Clutch System, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Clutch Release Cylinder Assy, Clutch Unit

Transmission Automatic:

Automatic Transaxle Assy, Torque Converter Clutch, Automatic Transaxle Fluid specifications

Driveline And Axles:

Front Drive Shaft, Rear Axle Beam, Differential Case Assy, Front Differential Oil Seal, Rear Axle Hub

Suspension Front:

Front Suspension System, Front Suspension Arm, Front Shock Absorber, Front Stabilizer Bar, Front Wheel Alignment

Suspension Rear:

Rear Suspension System, Rear Suspension, Rear Coil Spring, Rear Shock Absorber Assy, Rear Wheel Alignment

Steering System:

Steering System, Power Steering, Power Steering Link Assy, Steering Column, Steering Sensor, Horn, Horn Button Assy

Brakes System:

Brake System, Brake Master Cylinder, Brake Pedal, Brake Booster, Front Brake, Rear Brake, Brake Actuator, Brake Fluid specifications

Wheels And Tires:

Wheel And Tire System, Tire & Wheel, Front Axle Hub, Rear Axle Hub, Wheel Alignment procedures

Electrical Components:

Starter Assy, Generator Assy, Battery, Wiring Diagrams, Wire Harness Repair, Headlamp Assy, Taillight (Rear Combination Lamp Assy), License Plate Lamp Assy, Side Turn Signal Lamp Assy

Lighting System:

Headlamp Assy, Front Marker Lamp Assy, Rear Combination Lamp Assy, Side Turn Signal Lamp Assy, Center Stop Lamp Assy, License Plate Lamp Assy

Wiper And Washer:

Wiper And Washer System, Wiper Rubber, Windshield Wiper Motor Assy, Rear Wiper Motor Assy, Washer Nozzle

Air Conditioning HVAC:

Heater & Air Conditioner, Air Conditioning System, Receiver Condenser Assy, Pulley Compressor Assy, Heater Radiator Assy, Air Conditioning Blower Assy, Heater Or Boost Ventilator Control, Air Conditioner Refrigerant specifications

Interior And Body:

Body Repair, Hood, Front Bumper, Rear Bumper, Fender Panel Mudguard, Side Mudguard, Front Door, Rear Door, Back Door, Sun Roof, Windshield Glass, Rear Door Glass Weatherstrip, Front Door Glass Weatherstrip, Roof Headlining, Quarter Window Assy, Rear Door Window Frame Moulding, Roof Drip Side Finish Moulding

Seats And Restraints:

Seat, Seat Belt, Front Seat Belt, Rear Seat Belt, Seat Belt Warning System, Air Bag Sensor Side, Air Bag Sensor Front, Air Bag Sensor Rear, Passenger Air Bag Assy, Front Seat Airbag Assy, Curtain Shield Air Bag Assy, Seat Position Air Bag Sensor

Instrumentation And Controls:

Instrument Panel, Combination Meter, Steering Column, Steering Column controls, Headlamp Dimmer Switch Assy, Windshield Wiper Switch Assy, Center Cluster Module Switch, Shift & Select Lever Shaft, Floor Shift Assy

Audio Visual:

Radio Receiver Assy, Amplifier Antenna Assy, Front Speaker Assy, Rear Speaker Assy, Audio & Visual System

Safety Systems:

Supplemental Restraint System (SRS), Air Bag System diagnostics and components, Seat Belt Pre-tensioners, Skid Control Sensor, Yaw Rate Sensor, Parking Brake Lever, Parking Brake Cable, Floor Shift Parking Lock Cable, Shift Lock System, Parkneutral Position Switch, Seat Belt Warning System

Maintenance:

Scheduled maintenance, fluid changes (Engine Coolant, Brake Fluid, Transmission Fluids, Differential Oil), filter replacements (Oil Filter), lubrication

Diagnostics:

Troubleshooting guides for various systems, diagnostic trouble codes (DTCs), electrical circuit testing, sensor testing

Repair And Overhaul:

Detailed step-by-step instructions for component removal, installation, overhaul, and replacement (e.g., engine rebuild, transmission overhaul, brake caliper replacement, suspension component replacement)

Adjustment:

Valve Clearance adjustment, parking brake adjustment, clutch pedal free play adjustment

Wiring Diagrams:

Comprehensive wiring diagrams for all electrical systems, component location charts for wiring harnesses

Depth:

Comprehensive coverage suitable for professional technicians and experienced DIY enthusiasts, including advanced diagnostics, component specifications, and detailed repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (typically)

Printability:

Yes

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding:

Not Applicable (Digital Format)

Paper:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Engine Code:

2.4L "PowerTech" (RPO: ERG) / 4.0L "High Output" (RPO: ERH)

Displacement 2.4L:

2429 cc

Displacement 4.0L:

3956 cc

Horsepower:

154 hp @ 5200 rpm

Torque:

217 Nm (160 lb-ft) @ 4000 rpm

Horsepower:

190 hp @ 4600 rpm

Torque:

305 Nm (225 lb-ft) @ 3000 rpm

Fuel Delivery:

Sequential Multi-Port Fuel Injection (SFI)

Fuel Type:

Unleaded Gasoline

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum

Bore X Stroke 4.0L:

3.875 in x 3.312 in (98.4 mm x 84.1 mm)

🔧 Transmission

Transmission Type:

NV3550 5-Speed Manual

Transmission Type:

42RLE 4-Speed Automatic

Transmission Type:

NV3550 5-Speed Manual

Transfer Case:

NV231 Command-Trac (2-speed, part-time 4WD)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

156.7 inches (3980 mm)

Width:

66.5 inches (1689 mm)

Height:

70.5 inches (1791 mm)

Curb Weight Approx Manual:

3,348 - 3,578 lbs (1519 - 1623 kg)

Curb Weight Approx Auto:

3,455 - 3,653 lbs (1567 - 1657 kg)

Towing Capacity:

2,000 lbs (907 kg)

Ground Clearance:

approx. 8.5 inches (216 mm)

🛡️ Safety Features

NHTSA Front Driver:

Not rated (Vehicle design predates extensive modern NHTSA rating systems for this type of vehicle)

NHTSA Front Passenger:

Not rated (Vehicle design predates extensive modern NHTSA rating systems for this type of vehicle)

Braking:

Front Disc, Rear Drum (optional rear disc upgrade available on some trims/packages)

Traction Control:

Optional on some models

Airbags:

Driver and front passenger airbags standard. Optional side curtain airbags available.

Seat Belts:

Front 3-point, Rear lap and shoulder belts. Seat belt reminder system.

💡 Technology Features

Audio System:

Factory AM/FM/CD stereo systems with optional Infinity speaker upgrades. Basic radio functionality.

ABS:

Anti-lock Braking System available on some models/trims.

Auxiliary Input:

Not typically equipped with factory auxiliary audio input or Bluetooth.

Power Windows Locks:

Optional on some trims, manual operation was standard for base models.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (using synthetic blend or full synthetic oil recommended for the 4.0L).

Tire Rotation:

Every 7,500 miles (12,000 km)

Transmission Fluid Manual:

Check level as per manual; replacement generally at higher mileage or if contaminated.

Transmission Fluid Automatic:

Every 30,000 miles (48,000 km) or as specified in the manual, depending on driving conditions.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years

Spark Plugs 4.0L:

Champion Copper Plus (e.g., 438) every 30,000 miles or Platinum Plus every 100,000 miles.

Engine Oil 4.0L:

SAE 10W-30 API Service Category SG, SH, SJ or higher. (Check manual for specific approvals)

Engine Oil 2.4L:

SAE 5W-30 API Service Category SG, SH, SJ or higher. (Check manual for specific approvals)

Transmission Fluid Manual:

Mopar Manual Transmission Lubricant (or equivalent), typically SAE 75W-90 synthetic gear lubricant.

Transmission Fluid Automatic:

Mopar ATF+4 (or equivalent)

Transfer Case Fluid:

Mopar NV231 Transfer Case Fluid (or equivalent), typically SAE 75W-90 synthetic gear lubricant.

Differential Fluid:

API GL-5 SAE 75W-90 gear lubricant (consider LS additive if equipped with limited-slip differential).

Coolant:

Mopar Antifreeze/Coolant (HOAT) or equivalent, a 50/50 mix of antifreeze and deionized water.

Brake Fluid:

DOT 3

Common Wear Items:

Clutch wear, brake pad/rotor wear, suspension components (ball joints, tie rod ends), radiator leaks, exhaust system rust.

Engine 4.0L Specific:

Oil filter adapter O-ring leaks, exhaust manifold cracks (less common on later models), tappet noise.

Transmission Auto:

42RLE can be prone to overheating with heavy off-road use or towing; requires regular fluid maintenance.

📚 Vehicle History

Jeep Dna:

Descended from the original Willys MB military jeep, carrying a strong heritage of off-road prowess and utility.

Tj Generation:

The TJ generation (1997-2006) marked a significant departure from its leaf-sprung predecessor (YJ) by introducing coil springs for improved ride quality and off-road articulation, while retaining the iconic Jeep styling.

Manufacturing Location:

Toledo, Ohio, USA

Tj Production Span:

1997-2006

🏆 Awards & Recognition

Off Road Awards:

Jeep Wrangler consistently recognized for off-road capability and awarded by off-road enthusiast publications.