Positioning:
The 2002 Jeep Wrangler (TJ) continued Jeep's legacy of iconic off-road capability and open-air motoring, appealing to adventurers and enthusiasts seeking rugged, utilitarian transport.
Competitors 2002:
Primary competitors in the compact SUV segment, though the Wrangler occupies a niche with its dedicated off-road focus, included the Toyota RAV4, Honda CR-V, and Ford Escape, which were more car-like and less specialized.
Off Road Focus:
Solid front and rear axles, short wheelbase, high ground clearance, available locking differentials (Rubicon model), low-range gearing in transfer case.
Design:
Distinctive seven-slot grille, round headlights, exposed hinges, fold-down windshield, removable doors and top (soft top or hardtop).
Primary Coverage:
Comprehensive service and repair for the 2002 Jeep Wrangler (TJ chassis).
Specific Systems:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body.
Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Digital Download (likely PDF)
Engine Systems:
4.0L (High Output) inline-6 OHV MPI gasoline engine; diagnostics, fuel system, ignition system, cooling system, exhaust system, lubrication, engine mechanical, engine control systems (PCM).
Transmission Drivetrain:
NV3550 5-speed manual transmission, NP241OR 'Rock-Trac' NV241OR transfer case, Dana 30 front axle, Dana 35c rear axle, axle ratios, driveshafts, U-joints, differential service.
Suspension Steering:
Front and rear solid axle suspension (coil springs, control arms, track bars), shock absorbers, steering linkage, power steering system, wheel alignment.
Brakes:
Front disc brakes, rear drum brakes (or optional rear discs for Rubicon), ABS (if equipped), hydraulic system, parking brake.
Electrical Systems:
Wiring diagrams, charging system (alternator, battery), starting system, lighting, instrument cluster, power windows/locks (if equipped), horn, audio system, chime/buzzer system, electronic control modules (ECMs/PCMs), diagnostic trouble codes (DTCs).
Maintenance Procedures:
Fluid changes (engine oil, coolant, transmission fluid, transfer case fluid, axle fluid), filter replacements, spark plug service, battery maintenance, lubrication points.
Repair Procedures:
Engine overhaul, transmission rebuild, differential service, brake caliper/rotor replacement, suspension component replacement, steering system repair, electrical component diagnosis and replacement, HVAC system repair.
Troubleshooting:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, diagnostic trouble code (DTC) explanations and resolution steps.
Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts, covering diagnostics, disassembly, assembly, and repair procedures.
Engine Description:
4.0L (3952cc) Inline 6-Cylinder, Overhead Valve (OHV), Sequential Multi-Port Fuel Injection (MPI)
Horsepower:
181 hp @ 4,600 rpm
Torque:
222 lb-ft @ 3,200 rpm
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
19.0 US Gallons (71.9 Liters)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Long Life Antifreeze/Coolant (Orange) or equivalent.
Coolant Capacity:
11.8 US Quarts (11.2 Liters)
Transmission Type:
NV3550 5-Speed Manual Transmission
Transmission Type:
42RLE 4-Speed Automatic Transmission
Transfer Case:
NP241OR 'Rock-Trac' NV241OR Command-Trac (part-time, 2-speed, gear-driven with 2.72:1 low range)
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant (1806691) or equivalent API GL-3 spec, SAE 75W-90.
Automatic Transmission Fluid:
Mopar ATF+4 (MS-9602) or equivalent.
Transfer Case Fluid:
Mopar ATF+4 (MS-9602) or equivalent.
Wheelbase:
93.4 inches (2372 mm)
Length:
151.3 inches (3843 mm)
Width:
66.5 inches (1689 mm)
Height:
70.9 inches (1801 mm) (with hardtop)
Curb Weight:
Approx. 3,475 - 3,850 lbs (1,576 - 1,746 kg)
Gross Vehicle Weight Rating:
Approx. 4,850 lbs (2,200 kg)
Audio System:
Factory AM/FM/CD player, optional Infinity speaker system, basic analog climate controls.
ABS:
Optional Anti-lock Braking System (ABS).
Connectivity Features:
Limited by modern standards; primarily focused on basic vehicle operation. No advanced infotainment or smartphone integration.
Engine Oil Change:
Every 3,000 miles (4,800 km) for conventional oil, or 5,000 miles (8,000 km) for synthetic oil, under severe driving conditions (off-roading, towing). Refer to manual for optimal intervals.
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Transmission Fluid Change:
Manual: Inspect every 15,000 miles (24,000 km), change if necessary. Automatic: Every 60,000 miles (96,000 km) or as needed based on driving conditions.
Axle Fluid Change:
Every 30,000 miles (48,000 km) or when submerged in water.
Engine Oil Spec:
SAE 10W-30 API SJ or higher (for 4.0L engine). Check owner's manual for specific viscosity recommendations based on temperature.
Engine Oil Capacity:
5.0 US Quarts (4.7 Liters) with filter change.
Common Problems:
Steering box wear, oil filter adapter leaks (common on 4.0L), radiator leaks, CLUTCH SLAVE CYLINDER FAILURE (internal to bell housing on manual trans), wheel bearing failure, axle seal leaks, catalytic converter issues.
Common Problems Electrical:
Blend door actuator failure in HVAC system, intermittent gauge cluster issues, headlight switch failure.
Jeep Legacy:
Jeep's heritage traces back to World War II Willys MB Jeep, known for its ruggedness and off-road capability. This lineage is directly carried forward in the Wrangler.
Tj Generation:
The TJ generation, introduced for the 1997 model year, marked a significant departure from the YJ generation by returning to the traditional round headlights and adopting coil springs for the front suspension, improving ride quality and off-road articulation.
Manufacturing Plant:
Toledo, Ohio, USA
Model Year Range:
1997-2006 (TJ generation)
Off Road Awards:
Consistently recognized by off-road publications and enthusiasts for its class-leading articulation, durability, and modification potential.
Consumer Reports Reliability:
Historically varied, often noted for mechanical robustness but with some electrical and driveline quirks. The 2002 model's reliability ratings should be checked from contemporary reviews.
