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Jeep Wrangler 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Codes Chassis Code: TJ 👋 Introduction Market Position Category: Iconic Off-Road SUV Segment: Compact SUV, off-road focused Competitive Analysis Competitors:...
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Sku: 290903
Jeep Wrangler 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
2004
Codes
Chassis Code:
TJ
👋 Introduction
Market Position
Category:
Iconic Off-Road SUV
Segment:
Compact SUV, off-road focused
Competitive Analysis
Competitors:
Toyota 4Runner, Nissan Xterra, Suzuki Vitara (historically)
Key Features
Off Road Capability:
Renowned for its off-road prowess, solid axles (on TJ generation), robust 4WD systems
Design:
Classic Jeep styling, removable doors and top for open-air driving experience
Durability:
Built for rugged use and off-road adventures
📋 Manual Details
Coverage Areas
Covered Model Years:
2004
Covered Generations:
TJ
Page Count
Estimated Pages:
Approximately 2000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
All engine systems, including diagnostics, repair, and overhaul
Transmission:
Manual and Automatic transmission systems, including rebuilds
Drivetrain:
4WD system (NV241 GII transfer case), differentials, axles, driveshafts
Suspension:
Front and rear suspension components, steering system, alignment
Brakes:
Front and rear brake systems, ABS (if equipped), parking brake
Electrical:
Complete electrical schematics, lighting, ignition, charging system, starter, battery
Fuel System:
Fuel injection, fuel pump, lines, evaporative emissions system
Cooling System:
Radiator, water pump, thermostat, cooling fan, coolant specifications
Exhaust System:
Exhaust manifold, catalytic converter, muffler, emissions control
Body And Frame:
Body panel removal and installation, frame specifications, interior trim
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics and repair
Safety Systems:
Airbag system (if equipped), seat belt maintenance
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting charts, fault codes
Repair:
Component-level repair procedures, step-by-step instructions
Overhaul:
Complete engine and transmission rebuild procedures
Diagnostics:
On-Board Diagnostics (OBD-II) system information, diagnostic tool usage
Wiring Diagrams:
Comprehensive electrical wiring schematics for all systems
Specifications:
Torque specifications, clearances, adjustments
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically)
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4.0L Inline 6-Cylinder (OHV)
Engine Name:
PowerTech I6
Displacement:
3952 cc (241 cubic inches)
Bore X Stroke:
3.875 x 3.414 inches (98.4 x 86.7 mm)
Compression Ratio:
8.7:1
Performance
Horsepower:
190 hp @ 4600 RPM (approx.)
Torque:
235 lb-ft @ 3200 RPM (approx.)
Fuel System
Induction:
Electronic Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Engine Oil
Oil Type:
API SN or newer, SAE 5W-30
Oil Capacity:
6.0 US quarts (5.7 L) with filter change
Cooling System
Coolant Type:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (blue) or equivalent
Coolant Capacity:
12.1 US quarts (11.4 L)
🔧 Transmission
Standard
Transmission Type:
6-speed Manual Transmission (NSG370)
Optional
Transmission Type:
4-speed Automatic Transmission (42RLE)
Features
Manual Clutch:
Hydraulic clutch actuation
Automatic Fluid
Fluid Type:
Mopar ATF+4 (MS-9602) or equivalent
Fluid Capacity:
7.8 US quarts (7.4 L) dry fill
Manual Fluid
Fluid Type:
Mopar Manual Transmission Lubricant (MS-9224) or equivalent SAE 75W-90 synthetic
Fluid Capacity:
2.2 US quarts (2.1 L)
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
159.8 inches (4059 mm)
Width:
73.1 inches (1857 mm)
Height:
73.9 inches (1877 mm) (with hardtop)
Ground Clearance:
10.2 inches (259 mm)
Weights
Curb Weight:
Approximately 3,500 - 3,800 lbs (1588 - 1724 kg)
Tires
Standard Tire Size:
P215/75R15
Wheels
Wheel Bolt Pattern:
5x4.5 inches (5x114.3 mm)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3/5 stars (depending on configuration)
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Passive Features
Airbags:
Front airbags
Seat Belts:
3-point front seat belts with pretensioners, 3-point rear seat belts
💡 Technology Features
Infotainment
Audio System:
Base AM/FM stereo with CD player, optional Infinity sound system.
Driver Assistance
Features:
Limited driver assistance features. Primarily focused on mechanical capability.
Connectivity
Features:
No integrated Bluetooth or advanced connectivity features typically found in modern vehicles.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months, whichever comes first (severe service may require more frequent changes)
Tire Rotation Interval:
Every 6,000 miles or 6 months
Transmission Fluid Change Auto:
Every 60,000 miles or 60 months
Transmission Fluid Change Manual:
Every 100,000 miles or 120 months
Transfer Case Fluid Change:
Every 60,000 miles or 60 months
Differential Fluid Change:
Every 60,000 miles or 60 months
Fluid Specifications
Brake Fluid Type:
DOT 3
Power Steering Fluid Type:
Mopar Power Steering Fluid or equivalent
Known Issues
Common Issues:
Common issues include potential leaks (oil pan, valve cover, rear main seal), steering box wear, heater core leaks, and occasional ignition coil failures. Some TJ models may experience 'death wobble' if steering or suspension components are worn.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long and storied history dating back to its WWII origins, synonymous with off-road capability and freedom.
Model Evolution
Tj Generation:
The TJ generation (1997-2006) marked a significant return to Jeep's roots with the reintroduction of coil springs and a four-link front and rear suspension, replacing the leaf springs of the YJ.
Production
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently recognized by off-road publications and enthusiasts for its capability.
Ratings
Consumer Satisfaction:
Generally high customer satisfaction for its intended purpose, though reliability metrics can vary.
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