Jeep Wrangler Complete Workshop Service Repair Manual 2004 2005 2006

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Model Code: TJ Generation Generation: 2nd Generation (TJ) Codes Production Years: 1997-2006 Manual Coverage Years: 2004, 2005, 2006 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 453777

Tags: 2004 2005 2006 Car Cars Jeep Misc Wrangler

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Model Code:

Generation

Generation:

2nd Generation (TJ)

Codes

Production Years:

1997-2006

Manual Coverage Years:

2004, 2005, 2006

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV, Off-Road Vehicle

Target Audience:

Off-road enthusiasts, adventure seekers, owners prioritizing ruggedness and capability.

Competitive Analysis

Key Competitors:

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

Key Features

Off Road Capability:

Iconic solid front and rear axles, available locking differentials, robust four-wheel-drive systems, high ground clearance.

Versatility:

Removable doors, top, and windshield; convertible for open-air driving experiences.

Durability:

Known for its rugged construction and ability to withstand demanding off-road conditions.

📋 Manual Details

Coverage Areas

Major Systems Covered:

Engine, Transmission, Drivetrain, Brakes, Steering, Suspension, Electrical System, HVAC, Body, Interior

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures, component testing, torque specifications, timing belt/chain service, piston and ring installation, cylinder head reconditioning.

Fuel System:

Fuel pump testing, injector service, fuel pressure regulator diagnosis, evaporative emission control (EVAP) system troubleshooting.

Cooling System:

Radiator service, water pump replacement, thermostat testing, coolant specifications, fan clutch diagnosis.

Exhaust System:

Muffler and catalytic converter replacement, exhaust manifold repair, oxygen sensor testing and replacement.

Transmission Manual:

NV3550 (AX-15 successor) overhaul, clutch service, shift linkage adjustment, component diagnostics.

Transmission Automatic:

42RLE (optional) overhaul, torque converter replacement, valve body diagnosis, shift solenoid testing, fluid specifications.

Drivetrain 4X4:

NV241OR (242OR) transfer case service, Dana 30 front axle, Dana 35c rear axle overhaul, axle spline counts, differential fluid specifications, U-joint replacement, driveshaft service.

Brakes:

Front disc brake service (caliper, rotor, pad replacement), rear drum brake service (shoes, drum, wheel cylinder replacement), ABS system diagnostics, brake fluid specifications, bleeding procedures.

Steering:

Power steering system diagnosis, pump replacement, steering gear (steering box) adjustment and overhaul, tie rod end replacement, alignment specifications.

Suspension:

Front and rear suspension component replacement (shocks, springs, control arms, bushings), sway bar link replacement, lift kit installation considerations.

Electrical System:

Wiring diagrams for all circuits, fuse box locations, relay identification, battery charging system diagnosis, starter motor service, alternator testing.

Lighting System:

Headlight, taillight, turn signal, and interior lighting bulb replacement and troubleshooting, connector diagnostics.

Instrument Panel:

Gauge cluster removal and installation, warning light diagnosis, odometer troubleshooting.

HVAC System:

Air conditioning system service (refrigerant recharge, leak detection, compressor replacement), heater core replacement, blower motor testing, climate control system diagnosis.

Body Exterior:

Door panel removal, fender replacement, hood adjustment, bumper fascia repair, hardtop and soft top service, tailgate and door hinge repair.

Body Interior:

Seat removal and installation, dashboard disassembly, carpet replacement, sound deadening installation, trim panel repair.

Procedures Included

Routine Maintenance:

Oil change, filter replacement, tire rotation, brake inspection, fluid level checks, spark plug replacement, air filter replacement.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, OBD-II diagnostic trouble codes (DTCs) explained.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all systems.

Engine Rebuild:

Complete engine overhaul instructions, including disassembly, cleaning, inspection, machining specifications, and reassembly.

Transmission Rebuild:

Detailed procedures for rebuilding both manual and automatic transmissions.

Electrical Diagnostics:

Troubleshooting electrical circuits using wiring diagrams, multimeter usage, testing relays and switches, power and ground checks.

Body Repair:

Panel alignment, rust repair techniques, door and window glass replacement, soft top and hardtop maintenance.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Print Quality

Printability:

High-quality, printable pages

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Displacement Liter:

Engine Name:

Jeep 4.0L Inline-6 (Power Tech)

Engine Code:

ERH (for 2004-2006 models, though minor variations exist)

Performance

Horsepower Hp:

Torque Lb Ft:

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Sequential MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual

Manual Transmission Model:

NV3550

Optional

Transmission Type:

4-Speed Automatic

Automatic Transmission Model:

42RLE

Features

Transfer Case:

2-speed NV242OR (Command-Trac) with 4-Hi Part-Time, 4-Lo Part-Time

📐 Dimensions

Exterior

Wheelbase In:

Length In:

156.7

Width In:

Height In:

Ground Clearance In:

Weights

Curb Weight Lbs:

3600-3900 (approx.)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3 Stars (due to inherent design and purpose)

Active Features

Standard on all models for these years.

Passive Features

Airbags:

Driver and passenger front airbags.

Body Construction:

Body-on-frame construction, roll cage integrated into the cabin structure.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Infinity sound system with amplifier and subwoofer. Basic functionality.

Driver Assistance

Driver Assistance Features:

Limited to ABS. No advanced electronic driver aids found in modern vehicles.

Connectivity

Connectivity Options:

No integrated Bluetooth or USB ports from the factory. Aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, depending on driving conditions (severe duty recommended for off-road use).

Transmission Fluid Change Manual:

Every 50,000-60,000 miles.

Transmission Fluid Change Automatic:

Every 30,000-40,000 miles for normal use, sooner for severe use.

Coolant Flush:

Every 2 years or 30,000 miles.

Fluid Specifications

Engine Oil:

SAE 10W-30 (API SN or higher recommended)

Engine Coolant:

Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water.

Transmission Fluid Manual:

SAE 75W-90 Synthetic Gear Lubricant (API GL-5)

Transmission Fluid Automatic:

ATF+4 (MS-9602)

Transfer Case Fluid:

ATF+4 (MS-9602)

Rear Axle Fluid:

SAE 75W-140 Synthetic Hypoid Gear Lubricant (API GL-5, with friction modifier for LSD if equipped)

Front Axle Fluid:

SAE 75W-90 Synthetic Gear Lubricant (API GL-5)

Brake Fluid:

DOT 3

Known Issues

Common Issues:

Cracked exhaust manifolds, oil filter adapter leaks, death wobble (suspension/steering component wear), rear axle pinion seal leaks, heater core leaks, manual transmission bearing noise (some NV3550 models).

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct descendant of the original Willys MB WWII military Jeep, known for its off-road prowess.

Model Evolution

Tj Generation Introduction:

Introduced for the 1997 model year, replacing the YJ Wrangler. Key innovation was the move to coil spring suspension, offering a superior ride and articulation.

2004 Update:

Minor updates for 2004 included the introduction of the 42RLE automatic transmission, replacing the older 32RH. Other minor interior and exterior refinements were made throughout the TJ's lifecycle.

Production

Manufacturing Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized by off-road publications and enthusiasts for its segment-leading capability.