Positioning:
The Jeep Wrangler TJ is an iconic, go-anywhere off-road vehicle. It occupies a unique niche for enthusiasts seeking rugged capability and open-air driving experience.
Competition:
Competed with vehicles like the Toyota FJ Cruiser (later), Land Rover Defender (in some markets), and other specialized off-road SUVs, though its direct competitors were few due to its specific design.
Vehicle Features:
Body-on-frame construction, solid front and rear axles (a hallmark of its off-road prowess), removable doors and top, iconic Jeep styling.
Value:
This manual is essential for owners and technicians aiming to maintain, diagnose, and repair the 2004 Jeep Wrangler TJ with factory-correct specifications and procedures. Its comprehensive nature covers all facets of the vehicle.
Covered Models:
Wrangler SE, Wrangler X, Wrangler Sport, Wrangler Sahara, Wrangler Rubicon
Covered Engine Variants:
2.4L 4-cylinder DOHC Gasoline, 4.0L 6-cylinder Gasoline
Covered Manual Types:
Factory Service Manual, Factory Powertrain Manual, Factory Body Manual, Factory Chassis Manual, Factory Transmission Manual
Type:
Comprehensive Factory Service Workshop Manual
Format:
Likely Printed (Factory Service Manuals of this era are typically printed)
Mechanical Systems:
Engine, Fuel System, Exhaust System, Cooling System, Lubrication, Ignition, Clutch, Transmission, Transfer Case, Driveline, Differentials, Suspension, Brakes, Steering
Electrical Systems:
Audio/Video Systems, Chime/Buzzer Systems, Electronic Control Modules (ECMs), Engine Systems (electrical controls), Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Power System, Restraints (Airbags/Seatbelts), Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring Diagrams
Body Systems:
Body Construction, Frame, Bumpers, Heating & Air Conditioning, Emissions Control
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, inspections
Repair Diagnostics:
Detailed troubleshooting guides, diagnostic procedures for all systems, component removal and installation, component testing
Rebuilding:
Engine, transmission, transfer case, differential, and major component rebuilding procedures
Depth:
Factory-level diagnostic and repair procedures, including torque specifications, component clearances, electrical schematics, and system operation explanations
File Format:
Print (typical for this era)
Print Quality:
High-quality paper and printing, characteristic of OEM manuals
Binding Type:
Likely Professional Binding (e.g., spiral-bound or case-bound) for durability in workshop environments
Paper Type:
Durable, likely coated paper to withstand grease and workshop conditions
Engine 1 Variant:
2.4L DOHC 4-cylinder
Engine 1 Code:
Not explicitly provided, likely PowerTech or similar Chrysler designation
Engine 1 Displacement:
2351 cc (143.5 cubic inches)
Engine 1 Horsepower:
Approximately 147 hp @ 5200 rpm
Engine 1 Torque:
Approximately 165 lb-ft @ 4000 rpm
Engine 2 Variant:
4.0L Inline-6
Engine 2 Displacement:
3956 cc (242 cubic inches)
Engine 2 Horsepower:
Approximately 190 hp @ 4600 rpm
Engine 2 Torque:
Approximately 235 lb-ft @ 3200 rpm
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Transmission Options:
Manual Transmission: NV3550 5-speed (4.0L engine); NV1500 5-speed (2.4L engine, likely)
Transmission Options:
Automatic Transmission: 42RLE 4-speed automatic (for both engines)
Transfer Case Model:
New Process NV241 GII (for 4.0L); NV1500 (for 2.4L)
Transfer Case Gearing:
Command-Trac NV241 GII offers 2WD High, 4WD High, Neutral, 4WD Low (2.72:1 ratio)
Manual Fluid:
Refer to manual for specific fluid types (e.g., API GL-3 or GL-4, SAE 75W-90 or 75W-85)
Automatic Fluid:
Chrysler ATF+4 (MS-9602)
NHTSA Rollover Resistance:
3 stars (typical for this era, due to high center of gravity)
Airbags:
Driver and Passenger Front Airbags
Seat Belts:
3-point seat belts with pretensioners
Brakes:
Front: Ventilated Discs; Rear: Solid Discs
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional or part of electronic stability control (in some later models, less common for 2004 TJ)
Audio System:
Factory AM/FM/CD player, optional premium sound systems with subwoofer. Speaker configurations vary by trim.
Display Technology:
Basic analog gauges for speedometer, tachometer, fuel, and temperature. Warning lamps for various systems.
Driver Assistance Features:
Limited by era; primarily focused on core vehicle dynamics rather than electronic aids. ABS is the primary electronic safety feature.
Connectivity Options:
No integrated Bluetooth or smartphone connectivity. Aftermarket solutions are common.
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, refer to manual for specific usage conditions and synthetic oil recommendations.
Engine Air Filter Replacement:
Every 15,000-30,000 miles, or as needed based on driving conditions.
Spark Plug Replacement:
2.4L: ~100,000 miles; 4.0L: ~30,000-100,000 miles (depending on plug type, refer to manual)
Engine Oil Spec:
2.4L: SAE 5W-30; 4.0L: SAE 10W-30 or 5W-30 (refer to manual for exact API service classification, e.g., API SN/SP or equivalent)
Coolant Spec:
Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, typically Mopar OAT or equivalent, mixed 50/50 with distilled water.
Common Issues 4 0L:
Oil filter housing leaks, radiator leaks, exhaust manifold cracks, rear main seal leaks, TPS (Throttle Position Sensor) issues.
Common Issues Tj:
Death wobble (steering/suspension alignment issues), AC system leaks, interior tub rust, heater core issues, CLONK noise from transfer case linkage.
Common Issues Electrical:
Instrument cluster failure (common for '97-'01, less so for '04 but possible), melted wiring connectors in engine bay.
Jeep Heritage:
Jeep has a storied history dating back to World War II, synonymous with ruggedness, off-road capability, and military origins. The Wrangler lineage traces back to the original Willys Jeep.
Tj Generation:
The TJ generation (1997-2006) marked a significant return to Jeep's roots with the reintroduction of solid front and rear axles, which had been replaced by independent front suspension in the YJ Wrangler. This made the TJ highly sought after by off-road enthusiasts.
Production Period:
2004 model year
Manufacturing Plant:
Toledo Complex, Toledo, Ohio, USA
