Positioning:
Iconic off-road vehicle, known for its ruggedness and capability
Competitors:
Toyota 4Runner, Nissan Xterra, Suzuki Samurai (historically), Ford Bronco (historically)
Design:
Body-on-frame construction, solid front and rear axles, removable doors and top
Off Road:
Excellent articulation, ground clearance, short wheelbase, capable 4WD systems
Primary Coverage:
All repair procedures
Secondary Coverage:
Diagnostic, maintenance, repair, overhaul
Trim Levels:
Likely covers all available trim levels for 2004 including SE, Sport, Sahara, and Rubicon.
Type:
Factory Service Repair Manual
User Level:
Professional Mechanic and Advanced DIYer
Engine Mechanical:
Engine assembly, disassembly, overhaul, lubrication, cooling system, fuel system (injection/carburetion), exhaust system, engine performance tuning
Engine Electrical:
Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators, wiring diagrams
Transmission Drivetrain:
Manual transmission (AX-5, NV3550), Automatic transmission (42RLE), transfer case (NV241OR 'Rubicon Rock-Trac', NP231), drivelines, axles (Dana 30 front, Dana 35 rear, Dana 44 rear on Rubicon), differentials, hubs, CV joints
Brakes:
Hydraulic system, disc brakes (front/rear), anti-lock braking system (ABS) diagnostics, parking brake, brake bleeding procedures
Suspension Steering:
Front and rear suspension systems (solid axles with coil springs and control arms), steering gear, power steering system, wheel alignment
Electrical Body:
Lighting system, power windows, power locks, wipers, horn, instrument panel, interior trim, exterior trim, body panels, doors, hood, tailgate, convertible top
Climate Control:
HVAC system, air conditioning (A/C) system, heater, defroster
Chassis Frame:
Frame inspection, repair, corrosion protection
Maintenance:
Oil change, filter replacement, fluid checks and changes, spark plug replacement, belt replacement, filter replacements, general tune-ups
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, error code interpretation
Repair Overhaul:
Component disassembly, repair, reassembly, component replacement (engine, transmission, axles, brakes, suspension, steering, electrical components)
Installation:
Aftermarket accessory installation guidance where applicable to factory systems
Wiring Diagrams:
Comprehensive electrical system diagrams for all major components and circuits.
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds, advanced diagnostics
Diagnostic Tools:
Covers use of OBD-II scanners and diagnostic procedures for engine control systems.
Transmission Type:
5-Speed Manual (NV3550)
Transmission Type:
4-Speed Automatic (42RLE)
Clutch Type:
Hydraulic Actuation
Transfer Case Standard:
NV241OR 'Rock-Trac' (Rubicon), NP231 (Sport/Sahara)
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant (MS-9224) or equivalent (e.g., NV3550 calls for SAE 75W-90 GL-3/GL-4)
Automatic Transmission Fluid:
Mopar ATF+4 (MS-9602) or equivalent
Transfer Case Fluid:
Mopar NV241OR uses ATF+4 or equivalent, NP231 uses NP136 fluid or equivalent (SAE 75W-90 GL-4)
NHTSA Front Driver:
4 Stars (for 2000-2007 models)
NHTSA Front Passenger:
4 Stars (for 2000-2007 models)
IIHS Crash Test:
Acceptable (for 2000-2007 models)
ABS:
Available (standard on some trims/late production)
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
3-point front seat belts, 2-point rear lap belts (later models may have 3-point rear)
Oil Change Interval:
Every 3,000-6,000 miles or 6 months (whichever comes first, depending on driving conditions)
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Spark Plug Replacement:
Approx. 60,000-100,000 miles (depending on plug type, e.g., platinum/iridium)
Transmission Fluid Change:
Manual: Every 60,000-100,000 miles. Automatic: Every 30,000-60,000 miles or under severe service.
Engine Oil Type:
SAE 10W-30 (preferred for 4.0L) or SAE 5W-30 (for cooler climates or fuel economy)
Engine Oil Capacity:
6 US quarts (5.7 liters) with filter for 4.0L I-6
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (e.g., Mopar OAT/HOAT)
Coolant Capacity:
Approx. 10.8 US quarts (10.2 liters) for 4.0L I-6
Common Wear Items:
Clutch wear, U-joint failure, exhaust manifold cracks (4.0L), AC evaporator leaks, rear main seal leaks, water pump, radiator issues
Rubicon Specific:
Potential issues with electronic sway bar disconnect, differential locks.
