Jeep Wrangler TJ 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2005 Generation Generation Code: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Target...

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Type: Car

Vendor:

Sku: 490976

Tags: 2005 Car Cars Jeep Misc Wrangler TJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Generation

Generation Code:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking DIY repair and maintenance.

Competitive Analysis

Key Competitors Era:

Ford Bronco (earlier generations), Toyota 4Runner, Suzuki Samurai.

Key Features

Off Road Capability:

Renowned for its off-road prowess, solid axles, and available 4x4 systems.

Design Philosophy:

Iconic, rugged, open-air design with removable doors and top.

Manual Usefulness

Value Proposition:

Essential for owners to maintain, diagnose, and repair their 2005 Jeep Wrangler TJ efficiently and accurately.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service and repair coverage for the 2005 Jeep Wrangler TJ.

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, and overhaul procedures for all engine variants.

Transmission:

Coverage for manual and automatic transmissions, including disassembly, assembly, and component repair.

Drivetrain:

Front and rear axle, transfer case, differentials, driveshafts, and CV joints.

Suspension:

Front and rear suspension systems (leaf spring and coil spring), shock absorbers, control arms, steering knuckles.

Steering:

Steering gear, power steering system, tie rods, drag links, steering column.

Brakes:

Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic lines, master cylinder.

Electrical:

Complete electrical schematics, wiring diagrams, lighting, ignition, charging system, starting system, instrument cluster.

Body:

Body panel repair, doors, windows, seats, interior trim, convertible top mechanisms, exterior trim.

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair.

Fuel:

Fuel delivery system, fuel tank, fuel pump, fuel injectors, evaporative emissions system.

Cooling:

Radiator, cooling fan, water pump, thermostat, coolant flow.

Exhaust:

Exhaust manifolds, catalytic converter, mufflers, pipes.

Emission Control:

Emission control systems and diagnosis.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication.

Troubleshooting:

Diagnostic procedures, symptom analysis, fault code interpretation.

Repair:

Step-by-step repair instructions for all major components and systems.

Overhaul:

Complete engine and transmission rebuild procedures.

Replacement:

Component removal and installation instructions.

Adjustment:

Adjustments for various systems, e.g., parking brake, ignition timing (if applicable).

Technical Depth

Depth Level:

Comprehensive from basic maintenance to advanced diagnostics and complete component rebuilds.

Diagnostic Tools:

References to required diagnostic tools and procedures.

Torque Specifications:

Extensive listing of torque specifications for all fasteners.

Wiring Diagrams:

Detailed and accurate wiring diagrams for all vehicle systems.

Special Tools:

Identification and usage of special service tools.

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Quality Description:

High-resolution scans of original factory manual pages.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Description:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4.0L Inline 6-cylinder (MPI)

Engine Displacement:

3952 cc (241 cubic inches)

Bore X Stroke:

98.4 mm x 86.6 mm (3.87 in x 3.41 in)

Compression Ratio:

8.8:1

Performance

Horsepower Net:

190 hp @ 4600 rpm

Torque Net:

235 lb-ft @ 3200 rpm

4Cyl Horsepower:

147 hp @ 5200 rpm

4Cyl Torque:

190 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Code

Secondary Engine Option:

2.4L Inline 4-cylinder (MPI) - less common

🔧 Transmission

Standard

Transmission Type:

6-speed manual (NV3550)

Optional

Transmission Type:

4-speed automatic (42RLE)

Features

Transfer Case:

NV241OR (Rock-Trac) - standard on Rubicon, optional elsewhere

Transfer Case Gear Ratios:

4.0:1 (Rock-Trac), 2.72:1 (Command-Trac - standard)

Fluid Specifications

Manual Transmission Fluid:

NV3550: Mopar Manual Transmission Lubricant or equivalent SAE 75W-90 API GL-3/GL-4

Automatic Transmission Fluid:

42RLE: ATF+4 (Mopar) or equivalent

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width Body:

66.4 inches (1687 mm)

Height:

71.0 inches (1803 mm)

Ground Clearance:

10.5 inches (267 mm) (approx.)

Weights

Curb Weight:

3,700 - 4,000 lbs (1678 - 1814 kg) (approx., varies by configuration)

Gross Vehicle Weight Rating:

4,750 - 4,900 lbs (2154 - 2223 kg)

Towing Capacity:

2,000 lbs (907 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star

Active Features

Standard Anti-lock Braking System (4-wheel disc on most models)

Traction Control:

Optional

Passive Features

Airbags:

Driver and passenger front airbags

Rollover Protection:

Reinforced windshield frame and sport bar

💡 Technology Features

Infotainment

Audio System:

Optional AM/FM stereo with CD player, Sirius Satellite Radio available.

Speakers:

Typically 4 or 6 speakers, depending on trim level.

Driver Assistance

Cruise Control:

Available

Anti Theft:

Factory alarm system available.

Connectivity

Usb Aux Ports:

Not standard; aftermarket solutions common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months, whichever comes first (severe service) / 5,000 miles or 6 months (normal service).

Engine Air Filter:

Inspect every 15,000 miles, replace as needed. Replace every 30,000 miles.

Spark Plugs:

Recommend replacement every 100,000 miles (original equipment Champion copper plugs).

Transmission Fluid Auto:

Change every 30,000-40,000 miles, especially under heavy use.

Transmission Fluid Manual:

Change every 60,000 miles or as recommended by manual.

Fluid Specifications

Engine Oil Capacity:

6.0 quarts (5.7 Liters) with filter for 4.0L engine.

Engine Oil Viscosity:

10W-30 (preferred), 5W-30 for colder climates (refer to manual for detailed chart).

Coolant Type:

Chrysler/Mopar Antifreeze/Coolant (HOAT) - Orange or equivalent.

Brake Fluid Type:

DOT 3

Known Issues

Common Problems Engine:

Cracking of the 0331 cylinder head (early TJ models, largely resolved by 2005), Oil filter housing leaks, oil pressure sensor issues.

Common Problems Transmission:

NV3550 clutch pedal issues, 42RLE solenoid failures.

Common Problems Suspension:

Leaf spring fatigue (older models), worn control arm bushings, death wobble (due to worn steering/suspension components).

Common Problems Electrical:

Interior light failures, horn issues, dashboard illumination problems.

Common Problems Body:

RUST - especially on frame rails, body mounts, and rocker panels. Door hinge rust and sag, tailgate hinge rust.

Maintenance Schedules

Schedule Detail Level:

Detailed mileage and time-based schedules for all major maintenance items.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Continuous lineage of rugged, go-anywhere vehicles dating back to WWII Willys MB.

Model Evolution

Wrangler Lineage:

Direct descendant of the CJ series (Civilian Jeep).

Tj Generation Introduction:

Introduced for the 1997 model year, replacing the YJ Wrangler.

Tj Generation Key Features:

Return to coil springs for improved ride and articulation, Round headlights (unlike YJ's square headlights).

Production

Production Period Tj:

1997-2006

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

Consistently ranked as one of the most capable off-road vehicles available.

Ratings

Jeep Brand Loyalty:

Known for high owner loyalty and a strong enthusiast community.