🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Chassis Code:

TJ

Engine Codes Covered:

3.7L (226ci) V6 - ERB, 4.0L (242ci) Inline-6 - ERH

👋 Introduction

Segment:

Compact / Off-Road SUV

Target Audience:

Enthusiasts, off-roaders, owners seeking detailed maintenance and repair knowledge.

Key Competitors 2004:

Toyota Tacoma (4x4 variants), Nissan Xterra, Ford Bronco (prior generations), Suzuki Vitara.

Design Philosophy:

Body-on-frame construction, solid front and rear axles, removable tops (soft/hard), robust off-road capability.

Value Proposition:

Empowers owners to perform complex maintenance and repairs, saving on labor costs and extending vehicle lifespan.

Scope:

Provides the same level of detail as the official dealership service manuals.

📋 Manual Details

Primary Coverage:

North America

Engine Coverage:

3.7L V6, 4.0L Inline-6

Transmission Coverage:

NV3550 (5-Speed Manual), NV241OR (Command-Trac 4WD Transfer Case), 42RLE (4-Speed Automatic)

Drivetrain Coverage:

Dana 30 front axle, Dana 35 rear axle (standard, optional Dana 44 rear)

Estimated Pages:

Approximately 1500-2000 pages (typical for comprehensive factory-level manuals)

Type:

Factory Service Manual / Workshop Manual

Additional Type:

Includes Maintenance Schedule & Troubleshooting Guide

Primary Language:

English

Digital Format:

PDF

Searchable:

Yes, text-searchable PDF

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel and exhaust systems, ignition system, cooling system, lubrication system, starting and charging system, engine control systems (PCM).

Drivetrain:

Clutch system, manual transmission (NV3550), automatic transmission (42RLE), transfer case (NV241OR), driveshafts, front axle (Dana 30), rear axle (Dana 35/44).

Suspension Steering:

Front and rear suspension (leaf springs), shock absorbers, steering system (power steering pump, steering gear), wheel alignment specifications.

Brakes:

Front and rear brake systems (disc brakes all around), anti-lock braking system (ABS) if equipped, parking brake system, brake fluid specifications.

Electrical:

Battery, charging system, starting system, lighting system, instrument cluster, body electrical systems, wiring diagrams, fuses, relays, powertrain control module (PCM), anti-theft system.

Body:

Body construction, exterior trim, doors, windows, seats, interior trim, HVAC system (heating, ventilation, air conditioning), body sealant and vibration damping.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotation, inspection points.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical diagnostic procedures, diagnostic trouble codes (DTCs) interpretation.

Repair:

Step-by-step repair instructions for all major components and systems, disassembly and reassembly procedures, torque specifications, specifications and tolerances.

Diagnostics:

OBD-II diagnostics, scan tool usage, component testing, electrical circuit testing, pressure testing.

Depth:

Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts.

Detail Level:

Includes detailed schematics, exploded views, component locations, specifications, and procedures for complete overhauls.

📊 Manual Specifications

Type:

Digital (PDF)

Quality:

High-resolution scans, clear text and diagrams

Readability:

Designed for clear on-screen viewing and printable pages

Digital Format Consideration:

N/A (Digital product)

Digital Format Consideration:

N/A (Digital product)

⚙️ Engine Specifications

Base Engine:

4.0L (242ci) Inline-6 (ERH)

Optional Engine:

3.7L (226ci) V6 (ERB)

4.0L Horsepower:

190 hp @ 4600 rpm

4.0L Torque:

235 lb-ft @ 3200 rpm

3.7L Horsepower:

205 hp @ 5200 rpm

3.7L Torque:

235 lb-ft @ 4000 rpm

Type:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

ECU Type:

Chrysler's NGC (Next Generation Controller) or similar variants for engine control.

🔧 Transmission

Type:

NV3550 5-Speed Manual Transmission

Type:

42RLE 4-Speed Automatic Transmission

Transfer Case:

NV241OR (Command-Trac 2-speed part-time 4WD system)

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant (MS-9224) or equivalent API GL-4 SAE 75W-90

Automatic Transmission Fluid:

Mopar ATF+4 (MS-9602) or equivalent

Transfer Case Fluid:

Mopar NV241OR Transfer Case Lubricant (MS-9009) or equivalent SAE 75W-80 GL-4

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

159.3 inches (4046 mm)

Width:

73.1 inches (1857 mm)

Height:

72.1 inches (1831 mm) (soft top)

Ground Clearance:

Approx. 8.5 inches (216 mm) depending on tire size

Curb Weight:

Approx. 3500-3700 lbs (1588-1678 kg) depending on configuration

Towing Capacity:

2000 lbs (907 kg)

Payload Capacity:

Approx. 800-850 lbs (363-386 kg)

🛡️ Safety Features

NHTSA Rollover Resistance:

3/5 stars

IIHS Frontal Offset:

Good

ABS:

Optional Anti-lock Braking System (ABS) for rear wheels

Airbags:

Driver and passenger front airbags

Rollover Protection:

Factory-installed sport bar/roll cage

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional Infinity speaker system, SiriusXM Satellite Radio preparation.

Features:

Limited driver assistance systems by modern standards; primary focus on mechanical systems.

Features:

Basic connectivity, no integrated Bluetooth or smartphone mirroring.

🔧 Maintenance

Oil Change:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km)

Spark Plug Replacement:

Approx. 100,000 miles (160,000 km) for iridium plugs (if equipped).

Coolant Flush:

Every 30,000-60,000 miles (48,000-96,000 km) or 2-5 years.

Engine Oil Capacity:

4.0L: 5 quarts (4.7L), 3.7L: 5.5 quarts (5.2L)

Engine Oil Viscosity:

SAE 5W-30 (preferred for most conditions)

Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (MS-9769) or equivalent, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4

Common Wear Items:

Water pump, radiator, U-joints, clutch components (manual), exhaust system rust, frame rust (especially in northern climates), engine mounts.

Electrical Gremlins:

Can occur due to age and exposure, particularly with wiring harnesses, grounds, and the instrument cluster.

Transmission Issues:

NV3550 synchro wear, 42RLE solenoid pack failures.

📚 Vehicle History

Jeep Legacy:

Long-standing reputation for ruggedness and off-road capability, dating back to WWII Willys MB.

Tj Generation:

Second generation Wrangler (1997-2006), introduced coil springs replacing leaf springs for improved ride quality while retaining off-road prowess.

Tj Platform:

Shared a similar chassis and powertrain philosophy with its predecessor (YJ) but with significant updates in suspension and interior.

Manufacturing Location:

Toledo, Ohio, USA

Production Years Tj:

1997-2006

🏆 Awards & Recognition

Off Road Acclaim:

Consistently recognized by off-road publications and enthusiasts for its capability and customization potential.

Consumer Reports Typical Rating:

Variable, often scoring average to above average in predicted reliability depending on specific model year and powertrain.

Manual Certification:

Not applicable (third-party product based on factory data)