🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Generation:

TJ

Chassis Code:

TJ

👋 Introduction

Market Position:

Essential reference for Jeep Wrangler TJ owners and mechanics undertaking parts identification, replacement, or restoration projects. Caters to DIY enthusiasts and professional repair shops requiring accurate part sourcing.

Competitive Analysis:

Provides the official factory catalog, ensuring accuracy and completeness in part identification, which is superior to generic aftermarket parts guides. The digital format offers immediate access and portability.

Key Features:

Official factory illustrations, comprehensive part numbering, exploded view diagrams for intuitive part location, and digital accessibility for ease of use and printing.

📋 Manual Details

Coverage Areas:

Full Vehicle Parts Identification and Listing

Page Count:

Unknown (Digital PDF, actual page count may vary based on printing/display settings)

Manual Type:

Illustrated Parts List (IPL) Catalog Manual

Language:

English

Format:

Digital PDF Download

📖 Manual Coverage

Systems Covered:

Engine (mechanical, cooling, fuel, exhaust), Transmission (manual, automatic), Transfer Case, Drivetrain (front axle, rear axle, driveshafts, U-joints), Suspension (front, rear, steering), Brakes (front, rear, parking), Fuel System, Cooling System, Electrical System (wiring harnesses, lighting, ignition, starting, charging, instruments), Body (exterior panels, doors, hood, tailgate, bumpers, soft top/hardtop components), Interior (seats, dashboard, trim, controls), Wheels and Tires, Accessories, Emissions Control Systems

Procedures Included:

Parts identification via exploded diagrams, listing of individual part numbers, cross-referencing of parts, and component assembly/disassembly overview for parts ordering and recognition.

Technical Depth:

Detailed component breakdown, illustrating every part and its corresponding part number. Essential for accurate part sourcing, replacement, and understanding of vehicle assembly. Primarily focused on identification and procurement of parts, rather than repair procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable (quality depends on user's printer and settings)

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital PDF)

Compatibility:

All Windows, Mac, iOS, Android devices

Software Requirements:

Adobe Acrobat Reader (or compatible PDF viewer)

⚙️ Engine Specifications

Primary Engine:

4.0L (242 ci) Inline-6 OHV (AMC 242)

Engine Variants:

Also may cover 2.4L (148 ci) DOHC Inline-4 (PowerTech) for certain configurations, and potentially the 3.7L (226 ci) V6 (PowerTech) for later TJ models or specific markets, although the 4.0L is most prevalent for 2004 TJ.

Performance:

4.0L: Approx. 190 hp @ 4,600 rpm, 235 lb-ft @ 3,200 rpm

Fuel System:

Electronic Multi-Port Fuel Injection (MPI)

Cooling System:

Pressurized, liquid-cooled with radiator, fan, water pump, and thermostat. Specific coolant type: Mopar Antifreeze/Coolant (typically HOAT, 50/50 mix with distilled water).

🔧 Transmission

Standard:

NV3550 5-Speed Manual Transmission

Optional:

42RLE 4-Speed Automatic Transmission

Features:

Both transmissions are paired with the NP231 Command-Trac or NP241OR Rock-Trac (Rubicon) transfer cases, offering selectable 2WD High, 4WD High, and 4WD Low ranges.

Fluid Specifications:

Manual Transmission: NV3550 requires Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4 75W-90 gear oil). Automatic Transmission: 42RLE requires ATF+4 (MS-9602 or equivalent). Transfer Case: NP231/NP241OR require Mopar NP231/NP241 Transfer Case Lubricant (or equivalent 75W-90 gear oil).

📐 Dimensions

Exterior:

Wheelbase: 93.4 inches (SWB); Overall Length: 151.4 inches (SWB); Width: 66.5 inches (excluding mirrors); Height: 71.5 inches (soft top, variable with options)

Cargo:

Cargo Volume behind rear seat: ~14.6 cu ft; Cargo Volume with rear seat folded: ~46.4 cu ft

Weights:

Curb Weight: Approx. 3,400-3,800 lbs (depending on configuration and options)

🛡️ Safety Features

Ratings:

NHTSA frontal crash test ratings: Driver - 4 stars, Passenger - 4 stars. Side impact ratings were not consistently tested across all configurations for this model year by NHTSA.

Active Features:

Four-wheel Anti-lock Braking System (ABS) on all four wheels (standard on most models).

Passive Features:

Seat belts (front, rear), energy-absorbing steering column, reinforced windshield frame, body-on-frame construction, reinforced roll cage integrated into the body structure.

💡 Technology Features

Infotainment:

Base models featured a basic AM/FM/CD player. Optional upgrades included a premium sound system with more speakers, and some higher trims might have had an optional Infinity sound system. Bluetooth and advanced infotainment were not standard or widely available for this model year.

Driver Assistance:

Limited driver assistance features. ABS was the primary advanced safety technology. Cruise control was optional or standard on higher trims.

Connectivity:

No factory integrated connectivity features like USB ports or smartphone integration. Connectivity was limited to aftermarket solutions.

🔧 Maintenance

Service Intervals:

Oil Change: Every 3,000-5,000 miles or 6 months. Air Filter: Inspect every oil change, replace as needed (typically 15,000-30,000 miles). Spark Plugs: 100,000 miles (iridium). Coolant Flush: Every 5 years or 100,000 miles. Transmission Fluid (Manual): Inspect for leaks, replace if contaminated. Transmission Fluid (Automatic): Every 30,000-60,000 miles. Transfer Case Fluid: Every 30,000-60,000 miles. Differential Fluid: Every 30,000-60,000 miles. Brake Fluid: Every 2-3 years. Fuel Filter: Not typically user-replaceable, integrated into fuel pump module.

Fluid Specifications:

Engine Oil: 10W-30 (for 4.0L, check manual for temperature ranges and specific capacities, typically around 5-6 quarts with filter); 5W-30 (for 2.4L and 3.7L). Coolant: HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water. Power Steering Fluid: ATF+4 (MS-9602).

Known Issues:

Common issues include rust (especially on frame rails, rocker panels, and body mounts), CLUTCH CHATTER (especially with manual transmissions), front track bar wear, leaks from oil filter adapter housing, front axle seal leaks, and potential for distributor cap/rotor issues on older 4.0L engines. Some models may experience leaks from the windshield seal or door seals.

📚 Vehicle History

Brand Heritage:

Jeep has a storied history dating back to its military origins in World War II, evolving into a symbol of off-road capability and adventure. The Wrangler lineage directly traces back to the original Willys Jeep.

Model Evolution:

The TJ generation (1997-2006) marked a significant departure from its leaf-spring predecessors with the introduction of coil springs for a vastly improved on-road ride and handling. The 2004 model year saw minor updates and continued the successful formula.

Production:

Jeep Wrangler TJ models were manufactured in Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions:

The Jeep Wrangler TJ is consistently lauded for its off-road prowess and iconic design, often appearing on lists of 'Best 4x4s' or 'Most Iconic SUVs'.

Ratings:

Praised by automotive journalists for its go-anywhere capability and raw, unfiltered driving experience. Consumer reviews frequently highlight its durability and aftermarket support.