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Introduction
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Market Position
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Vehicle Segment:
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Compact Sport Utility Vehicle (SUV), Off-Road Focused
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Key Selling Points:
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Iconic off-road capability, rugged design, open-air experience (convertible top).
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Competitive Analysis
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Competitors 2000-2001:
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Toyota Tacoma (as an off-road focused truck), Suzuki Samurai (earlier competitor), Nissan Xterra, Ford Bronco (discontinued).
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Key Features
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Design Philosophy:
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Body-on-frame construction, solid front axle (on earlier TJ models, but leaf springs replaced by coils in TJ generation), live rear axle, robust drivetrain options.
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Body Styles:
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2-door convertible (soft top or optional hardtop), 2-door utility (hardtop).
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Off Road Systems:
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Command-Trac (2-speed transfer case) or optional Selec-Trac (full-time 4WD with low range) on some models, high ground clearance, short wheelbase.
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Manual Details
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Coverage Areas
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Primary Coverage:
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Complete Service and Repair
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Engine Coverage:
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4.0L Inline 6-Cylinder (PowerTech), 2.5L Inline 4-Cylinder (Vortec/AMC)
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Transmission Coverage:
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AX-5 (5-speed manual), NV3550 (5-speed manual), 30RH (3-speed automatic), 42RLE (4-speed automatic)
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Drivetrain Coverage:
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Front & Rear Axles (Dana 30, Dana 35C, Dana 44), Transfer Cases (NV231, NV241OR)
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Suspension Coverage:
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Front & Rear Coil Spring, Shock Absorbers, Control Arms, Stabilizer Bars
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Brake System Coverage:
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Front Disc, Rear Drum (standard), Front & Rear Disc (optional for some trims)
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Electrical System Coverage:
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Battery, Charging System, Ignition System, Lighting, Gauges, HVAC Controls, Powertrain Control Module (PCM), Body Control Module (BCM)
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Body And Chassis Coverage:
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Frame, Body Panels, Doors, Hood, Bumpers, Interior Trim, Seats, Convertible Top/Hardtop
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HVAC Coverage:
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Air Conditioning, Heating, Ventilation System Components and Operation
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Fuel System Coverage:
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Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Lines
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Cooling System Coverage:
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Radiator, Water Pump, Thermostat, Hoses, Fan
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Exhaust System Coverage:
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Exhaust Manifolds, Catalytic Converter, Muffler, Pipes
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Steering System Coverage:
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Steering Gearbox, Steering Column, Tie Rods, Power Steering Pump
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Tire And Wheel Coverage:
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Specifications, Maintenance, and Replacement
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Page Count
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Estimated Page Count:
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1500-2000+ (typical for comprehensive service manuals)
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Manual Type
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Type:
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Service and Repair Manual
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Scope:
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Diagnostic, Repair, Overhaul, and Maintenance Procedures
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Language
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Language:
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English
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Format
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Format:
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Downloadable Digital File (PDF)
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Manual Coverage
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Systems Covered
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Powertrain:
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Engine overhaul, fuel system diagnostics, cooling system repair, exhaust system replacement, ignition system troubleshooting, emission controls.
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Drivetrain:
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Clutch replacement, manual and automatic transmission repair, transfer case service, axle overhaul, driveshaft maintenance.
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Chassis And Suspension:
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Front and rear suspension component replacement, shock absorber and spring service, steering system overhaul, wheel alignment procedures.
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Braking System:
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Brake pad and rotor replacement, caliper and wheel cylinder service, hydraulic system bleeding, parking brake adjustment.
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Electrical Systems:
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Wiring diagrams, component testing, starter and alternator service, lighting system repair, instrument cluster diagnostics, horn operation.
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Body And Interior:
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Door and lock repair, window regulator service, seat removal and installation, convertible top maintenance, hardtop installation/removal, interior trim panel access.
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Heating Ventilation Air Conditioning:
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A/C system recharge, blower motor replacement, heater core service, refrigerant handling procedures.
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Procedures Included
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Preventative Maintenance:
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Oil and filter changes, fluid level checks and top-offs, tire rotation, belt and hose inspection, spark plug replacement.
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Troubleshooting:
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System-specific diagnostic charts, symptom-based troubleshooting guides, common problem identification.
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Repair And Overhaul:
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Detailed step-by-step instructions for component removal, installation, and rebuilding.
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Diagnostics:
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OBD-II (On-Board Diagnostics II) code retrieval and interpretation, sensor testing, actuator testing.
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Adjustments:
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Parking brake adjustment, clutch adjustment, idle speed adjustment, battery terminal cleaning.
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Specifications And Tolerances:
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Torque specifications, clearances, fluid capacities, electrical specifications.
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Technical Depth
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Depth Of Information:
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Comprehensive, covering routine maintenance to complete engine and transmission rebuilds.
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Diagnostic Capability:
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Advanced diagnostic procedures for electrical and mechanical systems.
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Special Tools:
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Identification and usage instructions for specialized tools required for specific repairs.
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Engine Specifications
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Primary Engine
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Engine 1 Displacement:
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4.0 Liters (242 cu. in.)
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Engine 1 Configuration:
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Inline 6-Cylinder (I6)
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Engine 1 Valvetrain:
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Overhead Valve (OHV), 12 Valves (2 per cylinder)
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Engine 1 Power Output:
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Approx. 182 hp @ 4,600 rpm
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Engine 1 Torque Output:
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Approx. 220 lb-ft @ 3,200 rpm
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Secondary Engine
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Engine 2 Displacement:
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2.5 Liters (150 cu. in.)
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Engine 2 Configuration:
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Inline 4-Cylinder (I4)
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Engine 2 Valvetrain:
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Overhead Valve (OHV), 8 Valves (2 per cylinder)
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Engine 2 Power Output:
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Approx. 114 hp @ 4,700 rpm
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Engine 2 Torque Output:
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Approx. 145 lb-ft @ 3,250 rpm
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Performance
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0-60 Mph Estimate:
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8.5-10.5 seconds (4.0L engine)
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Fuel Economy Est Mpg:
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14-17 City / 17-19 Highway (4.0L Automatic)
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Fuel System
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Fuel Delivery:
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Sequential Multi-Port Fuel Injection (MPI)
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Fuel Type:
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Unleaded Gasoline (87 Octane minimum recommended)
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Engine Management
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ECU Type:
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Chrysler Powertrain Control Module (PCM)
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Transmission
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Standard Manual
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Transmission 1 Type:
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AX-5 5-Speed Manual
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Transmission 1 Clutch:
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Hydraulically Actuated Single Dry Plate
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Optional Manual
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Transmission 2 Type:
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NV3550 5-Speed Manual (introduced later in TJ generation, often paired with 4.0L)
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Optional Automatic
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Transmission 3 Type:
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30RH 3-Speed Automatic
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Transmission 4 Type:
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42RLE 4-Speed Automatic (introduced later in TJ generation, often paired with 4.0L)
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Features
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Transfer Case Type:
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NV231 Command-Trac (2-speed, part-time 4WD) or NV241OR (2-speed, part-time 4WD, Rubicon model)
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Transfer Case Optional:
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NV242 Selec-Trac (2-speed, full-time 4WD with low range) on some models.
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Fluid Specification
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Manual Transmission Fluid:
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API GL-5, SAE 75W-90 (check specific manual for AX-5 vs NV3550)
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Automatic Transmission Fluid:
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Chrysler ATF+4 (MS-9602) (check specific manual for 30RH vs 42RLE)
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Fluid Capacity
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Manual Transmission Capacity Approx:
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2.4 Quarts (AX-5), 2.7 Quarts (NV3550)
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Automatic Transmission Capacity Approx:
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7.0 Quarts (30RH), 8.0 Quarts (42RLE)
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Dimensions
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Exterior
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Wheelbase:
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93.4 inches (2372 mm)
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Length:
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151.4 inches (3845 mm)
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Width Body:
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66.5 inches (1689 mm)
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Height To Top Of Hardtop:
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71.5 inches (1816 mm)
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Ground Clearance Unladen:
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Approx. 10 inches (254 mm)
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Approach Angle:
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Approx. 41 degrees
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Breakover Angle:
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Approx. 24 degrees
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Departure Angle:
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Approx. 37 degrees
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Weights
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Curb Weight Approx:
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3,400 - 3,800 lbs (1542 - 1724 kg)
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Gross Vehicle Weight Rating Gvwr Approx:
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4,600 - 4,900 lbs (2087 - 2223 kg)
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Towing Capacity Max Approx:
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2,000 lbs (907 kg)
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Payload Capacity Approx:
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1,000 - 1,200 lbs (454 - 544 kg)
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Tire Size
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Standard Tire Size:
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215/75R15 (some models), 30x9.50R15
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Optional Tire Size:
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31x10.50R15 (common upgrade, especially for Rubicon)
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Wheel Size
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Standard Wheel Size:
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15 x 7.0 inches
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Wheel Bolt Pattern:
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5 x 4.5 inches (5 x 114.3 mm)
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Safety Features
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Ratings
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NHTSA Frontal Crash Test Driver:
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4 stars (2000 model)
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NHTSA Frontal Crash Test Passenger:
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4 stars (2000 model)
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NHTSA Side Impact Front Seat Passenger:
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5 stars (2000 model)
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NHTSA Rollover Resistance:
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3 out of 5 stars (Statistical likelihood of rollover)
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Active Features
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ABS:
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Anti-lock Braking System (standard on front discs, optional on rear drums/discs depending on trim)
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Traction Control:
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Not widely available or standard on these model years.
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Passive Features
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Airbags:
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Driver and Passenger Frontal Airbags
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Seat Belts:
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Three-point front seat belts, Lap belts in rear (convertible)
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Roll Bar:
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Integral roll cage structure inherent to the body design for enhanced occupant protection.
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Technology Features
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Infotainment
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Audio System:
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Basic AM/FM/Cassette or AM/FM/CD player. Optional Infinity speaker system.
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Display:
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Analog gauges for speedometer, tachometer, fuel, and temperature. No digital display for infotainment or navigation.
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Driver Assistance
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Cruise Control:
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Available on higher trim levels.
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Anti Theft:
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Basic factory immobilizer system on some models.
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Connectivity
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Bluetooth:
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Not available from the factory.
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Usb Ports:
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Not available from the factory.
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Diagnostics
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OBD Ii Port:
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Standard OBD-II data link connector for emissions and powertrain diagnostics.
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Maintenance
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Service Intervals
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Oil And Filter Change:
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Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
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Air Filter Replacement:
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Every 15,000 miles (24,000 km) or 12 months, or more frequently in dusty conditions.
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Spark Plug Replacement:
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Approx. 60,000 - 100,000 miles (depending on spark plug type - copper vs. platinum/iridium).
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Coolant Flush And Replace:
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Every 30,000 miles (48,000 km) or 24 months.
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Transmission Fluid Change Automatic:
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Every 30,000 - 50,000 miles (48,000 - 80,000 km) or as per manual, especially if used for towing or severe duty.
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Transmission Fluid Change Manual:
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Every 50,000 - 75,000 miles (80,000 - 120,000 km).
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Brake Fluid Flush:
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Every 30,000 miles (48,000 km) or 24 months to prevent corrosion and maintain braking performance.
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Fluid Specifications
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Engine Oil Type:
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API SN or SP, SAE 10W-30 (preferred for 4.0L) or SAE 5W-30 for colder climates. Check manual for exact specification.
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Engine Oil Capacity 4.0L:
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5.0 Quarts (4.7 Liters) with filter
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Engine Oil Capacity 2.5L:
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4.5 Quarts (4.3 Liters) with filter
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Coolant Type:
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Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a green color. Do NOT mix with OAT (Orange) coolants.
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Power Steering Fluid:
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Mopar Power Steering Fluid or equivalent Dexron III/Mercon ATF.
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Brake Fluid Type:
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DOT 3
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Known Issues
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Common Weaknesses:
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Actuator rod for HVAC blend doors failing, minor oil leaks from valve cover or oil pan, rear main seal leaks on higher mileage 4.0L, clutch wear on manual transmissions, track bar wear on the front axle.
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Electrical Gremlins:
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Can be prone to minor electrical issues if wiring is compromised by off-roading or age; dashboard illumination can be intermittent.
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Frame Rust:
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In regions with road salt, frame rust can be a significant concern requiring careful inspection and potential treatment.
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Common Upgrades Covered
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Off Road Modifications:
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While not a primary focus for a stock repair manual, information on common modifications like lift kits, larger tires, and re-gearing axles might be indirectly touched upon in suspension or drivetrain sections if it pertains to stock specifications.
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Vehicle History
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Brand Heritage
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Jeep Legacy:
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Jeep's heritage dates back to World War II with the Willys MB, establishing a long-standing reputation for robust, go-anywhere capability.
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Model Evolution
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Tj Generation Introduction:
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The TJ Wrangler generation was introduced for the 1997 model year, replacing the YJ. It marked a significant shift with the adoption of coil springs for a smoother ride and improved articulation.
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Key Tj Changes Vs Yj:
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Coil spring suspension, a return to round headlights, and a significantly revised interior.
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2000-2001 Model Year Updates:
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Minor updates typically included revised interior trim, updated color options, and potential minor mechanical refinements. Specific details would be found within the manual itself.
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Production
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Production Location:
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Toledo, Ohio, USA (Jeep Assembly Plant)
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Production Years Tj:
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1997-2006
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