Engine:
Detailed diagnosis, repair, overhaul for 4.0L I6 and 2.4L I4 engines
Transmission:
Automatic (42RLE) and Manual (AX-5, NV3550) transmission service, rebuild, troubleshooting
Drivetrain:
Transfer case (NV231, NV241), Dana 30 (front) and Dana 35/Dana 44 (rear) axles, driveshafts, U-joints, differentials
Suspension:
Coil springs, shock absorbers, control arms, sway bars, steering linkage
Brakes:
Front disc, rear drum/disc brakes, ABS system (if equipped), master cylinder, power booster, lines, calipers, pads, rotors
Steering:
Power steering system, steering gear, column, tie rods, drag link
Electrical:
Comprehensive wiring diagrams, lighting, ignition, starting, charging system, battery, fuses, relays, body control modules
Emissions:
EVAP system, catalytic converter, O2 sensors, EGR (if equipped)
HVAC:
Air conditioning, heater, blower motor, controls, refrigerant system
Body:
Interior trim, exterior body panels, doors, hoods, fenders, bumpers, soft top/hardtop removal and installation
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, tire rotation
Troubleshooting:
Diagnostic charts, symptom-based problem diagnosis, fault codes
Repair:
Detailed step-by-step instructions for component replacement and repair
Rebuilds:
Engine, transmission, and axle overhaul procedures
Diagnostics:
OBD-II diagnostics, sensor testing, circuit testing
Specifications Data:
Torque specifications, alignment data, clearances, tolerances
Body Repair:
Body panel alignment, collision repair data, frame straightening procedures
Exhaust System:
Diagnosis and replacement of exhaust manifolds, catalytic converters, mufflers, and pipes
Fuel System Repair:
Fuel pump replacement, fuel filter service, fuel injector diagnosis and cleaning
Depth:
Comprehensive, suitable for professional technicians and advanced DIYers
Wiring Diagrams:
Detailed, section-specific wiring schematics for all major systems.
Diagnostic Codes:
Includes common Diagnostic Trouble Codes (DTCs) and their interpretation.
Specifications Tables:
Extensive tables of torque values, measurements, and clearances.
Engine 1:
4.0L (3952cc) Inline-6 OHV "Power Tech I-6" (242 ci)
Engine 1 Power:
Approx. 190 hp @ 4600 rpm
Engine 1 Torque:
Approx. 235 lb-ft @ 3200 rpm
Engine 2:
2.4L (2429cc) Inline-4 OHV "Power Tech" (148 ci)
Engine 2 Power:
Approx. 145 hp @ 5200 rpm
Engine 2 Torque:
Approx. 190 lb-ft @ 3600 rpm
Compression Ratio 4.0L:
8.8:1
Bore Stroke 4.0L:
3.88 in x 3.41 in (98.5 mm x 86.6 mm)
Fuel Delivery:
Multi-port Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
ECM:
Chrysler NGC (Next Generation Controller) or similar
Manual Transmission:
AX-5 5-speed manual (standard on 2.4L, some 4.0L models)
Manual Transmission Optional:
NV3550 5-speed manual (heavy-duty, standard on most 4.0L models)
Automatic Transmission:
42RLE 4-speed automatic (optional on 4.0L models)
Transfer Case Options:
NV231 (Command-Trac) part-time, NV241OR (Rubicon Rock-Trac) part-time with 4:1 low range
Manual Fluid:
Refer to manual for specific fluid type (e.g., NV3550 often uses Mopar Manual Transmission Lubricant or equivalent)
Automatic Fluid:
ATF+4 (Mopar)
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months (refer to manual for specific oil type and interval)
Transmission Fluid Change:
Automatic: 60,000-100,000 miles; Manual: Inspect, replace as needed or at higher mileage intervals (consult manual)
Coolant Flush:
Every 30,000-60,000 miles or 2-5 years
Spark Plugs:
4.0L I6: Approx. 100,000 miles (Long-life plugs); 2.4L I4: Approx. 60,000-100,000 miles (Refer to manual)
Engine Oil 4.0L:
SAE 10W-30 (API Certified), capacity 5 quarts with filter
Engine Oil 2.4L:
SAE 5W-30 (API Certified), capacity 4 quarts with filter
Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent long-life coolant (typically Mopar OAT)
Power Steering Fluid:
ATF+4 (Mopar) or Mopar Power Steering Fluid
Common Issue Cooling:
Leaking radiator, heater core issues, thermostat housing leaks
Common Issue Electrical:
Instrument cluster problems, headlight switch issues, intermittent electrical gremlins
Common Issue Suspension Steering:
Worn track bar, ball joints, tie rod ends, steering box looseness
Common Issue Drivetrain:
U-joint failure, axle seal leaks, differential gear wear (especially with off-road use)
