🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Platform:

TJ

👋 Introduction

Market Position:

The 2004 Jeep Wrangler TJ represents a highly capable and iconic off-road vehicle, known for its distinctive styling and legendary capability. This parts catalog is indispensable for owners, mechanics, and restoration specialists looking to maintain or rebuild these vehicles.

Competitive Analysis:

In its era, the TJ Wrangler competed with vehicles like the Toyota Tacoma 4x4, Ford Bronco (though discontinued by 2004, its legacy remained), and Suzuki Samurai. The TJ's unibody construction was a departure for Jeep, but its solid axles and robust design set it apart.

Key Features:

Solid front and rear axles, coil spring suspension, iconic seven-slot grille, removable doors and top, exceptional off-road articulation and ground clearance. The 2004 model year saw minor updates and the continued availability of the powerful 4.0L inline-6 engine.

📋 Manual Details

Coverage Areas:

Comprehensive parts catalog for all systems and components of the 2004 Jeep Wrangler TJ, including engine, drivetrain, chassis, suspension, brakes, steering, electrical, body, and interior.

Page Count:

Estimated 1000+ pages (typical for comprehensive parts catalogs of this era).

Manual Type:

Parts Catalog

Language:

English

Format:

PDF

Distribution:

Instant Download

Platform Compatibility:

Windows and Mac operating systems.

📖 Manual Coverage

Systems Covered:

Engine mechanical (4.0L, 2.4L), engine fuel & emissions, cooling system, exhaust system, transmission (manual & automatic), transfer case, axles (Dana 30 front, Dana 35c/Dana 44 rear), driveshafts, steering system, suspension (front & rear), brake system (front disc, rear drum/disc), wheels & tires, electrical system (battery, starting, charging, ignition, lighting, instruments, wiring harnesses), body (exterior panels, doors, hood, fenders, bumpers, top systems), interior (seats, dashboard, trim, controls).

Procedures Included:

Detailed exploded views of all assemblies, precise part numbers for every component, interchangeability information, assembly and disassembly sequences for common components, and illustrations showing component relationships. Not a repair manual, but essential for identifying and ordering correct replacement parts.

Technical Depth:

Highly detailed for parts identification. Provides OE (Original Equipment) part numbers, aftermarket cross-references where applicable. Critical for correct part selection in repairs, restorations, and modifications. Illustrates fasteners, brackets, and small components often overlooked.

Parts Identification:

Crucial for identifying correct replacement parts for all JK Wrangler components, including fasteners, clips, and small hardware items essential for proper assembly.

Vin Decoding Support:

While not explicitly a VIN decoder, the catalog's structure often aligns with VIN sequences for specific model year and trim variations, aiding in correct part identification based on vehicle configuration.

Illustration Type:

High-quality exploded view diagrams with clear labeling of each part and its associated part number.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Print Quality:

High-resolution, suitable for printing. Clear and crisp diagrams and text.

Binding Type:

Digital (No physical binding)

Paper Type:

N/A (Digital format)

Searchability:

PDF format typically allows for text searching, enabling quick location of specific part numbers or descriptions.

⚙️ Engine Specifications

Primary Engine:

4.0L (242 cu in) OHV Inline-6 (PowerTech)

Horsepower 4.0L:

190 hp @ 4600 rpm

Torque 4.0L:

235 lb-ft @ 3200 rpm

Horsepower 2.4L:

154 hp @ 5800 rpm

Torque 2.4L:

164 lb-ft @ 4000 rpm

Secondary Engine:

2.4L (147 cu in) DOHC Inline-4 (World Engine)

Fuel System:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Cooling System Capacity:

Approx. 10.5 quarts (9.9 liters) for 4.0L engine

🔧 Transmission

Standard Transmission:

6-Speed Manual (NV3550)

Optional Transmission:

4-Speed Automatic (42RLE)

Transfer Case Standard:

2-Speed NV241 GII Command-Trac (Part-time, 4WD)

Transfer Case Gear Ratios:

2.72:1 low range

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4, SAE 75W-90)

Automatic Transmission Fluid:

ATF+4 (Mopar)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

72.9 inches (1852 mm) (with soft top)

Curb Weight Approx:

3,500 - 3,800 lbs (1588 - 1724 kg)

Gross Vehicle Weight Rating Gvwr:

4,500 lbs (2041 kg)

Cargo Volume Behind Rear Seat:

30.7 cu ft (0.87 m³)

Cargo Volume Max:

69.2 cu ft (1.96 m³)

Wheel Size Standard:

15-inch or 16-inch steel or alloy wheels

Tire Size Standard:

215/75R15, 225/75R16, or 30x9.5R15 (depending on trim and options)

Bolt Pattern:

5x4.5 inches (5x114.3 mm)

🛡️ Safety Features

NHTSA Rollover Rating:

4 out of 5 stars (typically)

Active Features:

Four-wheel Anti-lock Brakes (4WABS) on front discs and rear drums/discs (depending on configuration).

Passive Features:

Driver and front passenger airbags, seat belts with pretensioners, reinforced body structure.

Recall Information:

Potential recalls may exist for various components. Owners should consult NHTSA or Jeep for specific vehicle recall status.

💡 Technology Features

Infotainment Options:

Basic AM/FM/CD or Cassette player with optional Infinity speaker system. Limited digital integration by modern standards.

Driver Assistance Features:

Very limited. Primarily focused on core mechanical and safety systems. No advanced electronic driver aids like adaptive cruise control or lane keeping assist.

Connectivity Options:

No factory integrated Bluetooth or smartphone connectivity. Aftermarket solutions are common.

🔧 Maintenance

Oil Change Interval 4.0L:

Every 3,000 - 5,000 miles (or as per owner's manual, depending on driving conditions).

Engine Coolant Change Interval:

Every 30,000 miles or 2 years for original fill (check manual for specifics).

Transmission Fluid Change Interval:

Manual: Consult manual. Automatic: Every 30,000 - 60,000 miles (ATF+4 is generally considered a 'lifetime' fluid by some, but regular changes are recommended).

Engine Oil Specification:

SAE 10W-30 (for 4.0L) or 5W-30 (for 2.4L), API Certified.

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (or equivalent HOAT).

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid (or equivalent ATF+4).

Transfer Case Fluid:

Mopar NV241 GII Transfer Case Fluid (or equivalent SAE 75W-90 GL-5 synthetic).

Axle Fluid Front:

SAE 80W-90 GL-5 gear lubricant (check manual for specific friction modifier requirements for LSD/trac-lok equipped axles).

Axle Fluid Rear:

SAE 80W-90 GL-5 gear lubricant (check manual for specific friction modifier requirements for LSD/trac-lok equipped axles).

Known Issues:

Common issues can include: radiator leaks (especially plastic tanks), rear main seal leaks (4.0L), cracked exhaust manifolds (4.0L), clutch wear, suspension component wear (bushings, ball joints), and evap system leaks (e.g., gas cap seal). Cooling system maintenance is crucial.

Common Electrical Issues:

Corrosion on bulkhead connectors, faulty clock spring in steering wheel, alternator output issues.

Oil Filter Part Number Examples:

Mopar: MO-090, Fram: PH8A, Wix: 51515

Air Filter Part Number Examples:

Mopar: 53007204, Fram: CA8755, Wix: 42174

📚 Vehicle History

Brand Heritage:

Jeep has a storied history rooted in World War II military vehicles, evolving into a symbol of ruggedness, adventure, and off-road prowess. The Wrangler is the direct descendant of the original Jeep CJ.

Model Evolution:

The TJ generation (1997-2006) marked a significant evolution from its YJ predecessor, reintroducing the beloved round headlights and coil spring suspension for improved ride comfort and off-road articulation. The 2004 model year continued to refine this platform.

Production Location:

Toledo, Ohio, USA

Production Years Tj:

1997-2006

Model Variants 2004:

SE, Sport, Sahara, Rubicon. Each offered different standard equipment and off-road packages.