🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2005

Chassis Code:

TJ

👋 Introduction

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Unique Selling Proposition:

Iconic off-road capability, open-air driving experience, go-anywhere design

Competitors 2005:

Toyota Tacoma (off-road variants), Nissan Xterra, Suzuki Vitara (Grand Vitara), Ford Bronco (discontinued but relevant legacy)

Design Philosophy:

Body-on-frame construction, solid axles (front and rear), removable doors and top, high ground clearance

Manual Value Proposition:

Empowers owners and independent technicians with factory-level knowledge, reducing reliance on dealerships and promoting DIY maintenance

📋 Manual Details

All Models Covered:

Yes

Repair Scope:

A-Z

Information Type:

Vehicle Specific

Target Audience:

Dealership Technicians

Approximate Pages:

1500+

Type:

Factory Service Manual (FSM)

Language:

English

Format:

Print

📖 Manual Coverage

Engine Mechanical:

Full overhaul, diagnostics, tuning, lubrication, cooling, fuel delivery, exhaust

Engine Electrical:

Ignition system, sensors, actuators, ECU, starting and charging systems

Transmission Manual:

NV3550: Clutch, gearbox internal repair, linkage, service

Transmission Automatic:

42RLE: Internal components, valve body, torque converter, cooling, diagnostics

Drivetrain:

NP231J Transfer Case (NV231): Operation, disassembly, repair, fluid specifications; Dana 30 front axle, Dana 35 rear axle: Hubs, differentials, gears, seals, bearings, U-joints

Suspension:

Front and rear coil springs, shock absorbers, control arms, track bars, bushings, sway bars, alignment specifications

Steering:

Power steering system, steering gear, linkages, pump, fluid, column

Brakes:

Front and rear disc brakes (ABS and non-ABS), hydraulic system, calipers, rotors, pads, parking brake, bleeding procedures, specifications

Body Chassis:

Frame, body panels, doors, hood, windshield, interior trim, convertible top mechanism, fasteners, rust prevention

Electrical Body:

Lighting, wipers, horn, power windows, locks, mirrors, HVAC controls, seats, security system, audio system wiring

HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant handling, diagnostics

Fuel System:

Fuel pump, filter, injectors, lines, tank, evaporative emissions (EVAP) system

Exhaust System:

Catalytic converter, mufflers, pipes, hangers, O2 sensors

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, battery maintenance

Troubleshooting:

Diagnostic flowcharts, symptom analysis, component testing

Component Replacement:

Detailed step-by-step instructions for replacing all major and minor components

Rebuild Procedures:

Engine, transmission, transfer case, axle differentials

Diagnostics Electrical:

Wiring diagrams, connector pinouts, scan tool data interpretation, component resistance/voltage testing

Specifications Data:

Torque values, clearances, fluid capacities, electrical parameters

Depth:

Complete factory-level repair and maintenance guidance

Detail Level:

Detailed diagrams, illustrations, and step-by-step instructions

Diagnostic Focus:

In-depth diagnostic procedures for all major systems

📊 Manual Specifications

Digital Equivalent:

Likely PDF, often provided as digital downloads or on CD-ROM for older manuals

Print Quality:

High-resolution printing, clear diagrams and text

Binding:

Typically spiral-bound or perfect-bound for durability in a workshop environment

Paper Quality:

Durable, often glossy or semi-gloss paper to resist shop fluids

⚙️ Engine Specifications

Engine Code:

4.0L (137 CID) SOHC V6 - 'SIx' (Optional, not standard for 2005 TJ unless specified)

Standard Engine 2005:

2.4L (148 CID) DOHC I4 - 'PowerTech' (EJ24) - Standard on SE and Sport trims

Optional Engine 2005:

4.0L (242 CID) OHV I6 - 'High Output' (62TE) - Standard on Sahara and Rubicon trims, optional on others

2.4L Horsepower:

147 hp @ 5200 rpm

2.4L Torque:

165 lb-ft @ 4000 rpm

4.0L Horsepower:

190 hp @ 4600 rpm

4.0L Torque:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI), Multi-point fuel injection (MPFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Spark Plug Recommendation:

Champion Copper Plus (e.g., RC12ECC) or equivalent iridium plugs

Engine Oil Type:

SAE 10W-30 API Certified (Chrysler MS-6395 compliant)

🔧 Transmission

Standard Transmission Type:

NV3550 5-Speed Manual

Optional Transmission Type:

42RLE 4-Speed Automatic

Transfer Case:

NV231J Command-Trac (2WD High, 4WD High, 4WD Low, Neutral)

Manual Transmission Fluid:

ATF+4 (MS-9602) or equivalent specified manual transmission fluid

Automatic Transmission Fluid:

ATF+4 (MS-9602) exclusively

Transfer Case Fluid:

Mopar Manual Transmission Lubricant (MS-9224) or equivalent SAE 75W-90 synthetic gear oil

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm) (2-door)

Width:

66.5 inches (1689 mm) (body)

Height:

70.1 inches (1781 mm) (with hardtop)

Ground Clearance:

10.0 inches (254 mm) (approximate, varies with tire size)

Curb Weight:

3,490 - 3,800 lbs (1583 - 1724 kg) (approximate, depending on configuration)

Towing Capacity:

2,000 lbs (907 kg)

Standard Wheel Size:

15 x 8 inches

Standard Tire Size:

LT215/75R15 (Sport), LT225/75R16 (Sahara/Rubicon)

Bolt Pattern:

5 x 4.5 inches (114.3 mm)

🛡️ Safety Features

NHTSA Rollover Resistance:

4/5 Star (for 2005 model year, specific results may vary slightly)

ABS:

Standard on all 2005 Wranglers

Airbags:

Driver and passenger front airbags

Seatbelts:

Three-point front seat belts, lap belts in rear

Rollover Protection:

Factory-installed sport bar (roll cage)

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional Infinity speaker system, optional subwoofer

User Interface:

Basic dashboard layout, manual climate controls, traditional analog gauges

Features 2005:

Limited; primarily focused on core vehicle function. ABS is standard. No advanced electronic driver aids.

Features 2005:

Basic connectivity through audio system. No Bluetooth or USB ports typically found in base configurations.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on conditions

Spark Plug Replacement:

Copper: 30,000 miles (48,000 km); Iridium: 100,000 miles (160,000 km) (if applicable)

Coolant Flush Interval:

Every 100,000 miles (160,000 km) or 5 years

Transmission Fluid Service:

Manual: Inspect every 30,000 miles; Automatic: Every 60,000 miles (100,000 km) or 4 years

Engine Oil Capacity:

4.0L I6: 6 US quarts (5.7 L); 2.4L I4: 5 US quarts (4.7 L) with filter

Coolant Type:

Chrysler OAT (Orange) Antifreeze/Coolant (MS-9769)

Brake Fluid Type:

DOT 3

Common Weaknesses:

Front sway bar disconnect issue (Rubicon), minor oil leaks from valve cover or oil pan gaskets, exhaust manifold cracks (4.0L I6), potential for interior water leaks around doors and windshield seals, automatic transmission (42RLE) not as robust as manual for extreme off-roading.

Rear Axle Concerns:

Dana 35 rear axle in non-Rubicon models can be a limiting factor for very aggressive off-road use and larger tire sizes compared to the Dana 44 in the Rubicon.

📚 Vehicle History

Brand Legacy:

Jeep's lineage traces back to the Willys MB used in WWII, establishing a reputation for ruggedness and off-road capability.

Tj Generation:

The TJ generation (1997-2006) represented a significant modernization for the Wrangler, introducing coil springs and a new suspension geometry while retaining the iconic inline-six engine and solid axle design.

2005 Updates:

For 2005, key updates included the introduction of the 4.0L 'High Output' engine as standard on Sahara and Rubicon trims, the availability of the new 4.0L 'SIx' V6 engine (though less common/carried over from previous years in some contexts), improved interior comfort features, and minor cosmetic revisions.

Assembly Location:

Toledo North Complex, Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Acclaim:

Consistently recognized as a benchmark for off-road capability by automotive journalists and enthusiast publications. Competes in a niche segment defined by its off-road prowess rather than comfort or fuel economy.