🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2005

Chassis Code:

TJ

Product Code:

JL-TJ2005-PARTS

👋 Introduction

Market Position:

The 2005 Jeep Wrangler TJ represents the final iteration of the iconic CJ-derived Wrangler, beloved for its rugged off-road capability and timeless design. This parts manual is essential for owners and technicians dedicated to maintaining and restoring these vehicles with original or equivalent components.

Competitive Analysis:

Competed against other compact SUVs but stood out with its superior off-road prowess. This manual provides specific part numbers critical for maintaining its unique off-road focused architecture, differentiating it from more car-based SUV competitors.

Key Features:

This parts manual is distinguished by its comprehensive coverage of the TJ generation, known for its coil-spring suspension, a significant upgrade from earlier leaf-sprung Wranglers. It details parts for both 4.0L and 2.4L engine options, and the popular manual and optional automatic transmissions.

📋 Manual Details

Coverage Areas:

All components and systems of the 2005 Jeep Wrangler TJ

Page Count:

Estimated 500-700 pages (typical for comprehensive parts catalogs of this era)

Manual Type:

Parts Manual / Parts Catalog

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered:

Engine assembly, fuel system, cooling system, exhaust system, drivetrain (transfer case, axles, driveshafts), manual transmission, automatic transmission, clutch, brakes (front disc, rear drum), steering, suspension (front solid axle, rear solid axle), electrical system, lighting, body panels, interior trim, seating, climate control, emissions control, wheels and tires.

Procedures Included:

Component identification, part number cross-referencing, assembly diagrams, exploded views of sub-assemblies, installation sequences (implied by part placement and diagrams), fastener specifications (bolt sizes, torque values often associated with parts).

Technical Depth:

Highly detailed, focusing on the precise identification and sourcing of original equipment manufacturer (OEM) replacement parts. Provides granular detail on how components fit together.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Print Quality:

High resolution, suitable for clear printing of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

4.0L (242 cu in) Inline 6-Cylinder OHV (P0420 engine code)

Secondary Engine:

2.4L (147 cu in) Inline 4-Cylinder DOHC (ED3 engine code)

Horsepower:

190 hp @ 4,600 rpm

Torque:

235 lb-ft @ 3,200 rpm

Horsepower:

150 hp @ 5,900 rpm

Torque:

165 lb-ft @ 4,000 rpm

Fuel System:

Multi-port Electronic Fuel Injection (MPI)

Cooling System:

Pressurized, liquid-cooled with electric fan (for 2.4L) or fan clutch (for 4.0L)

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug for 4.0L; Distributorless ignition system with coil pack for 2.4L

🔧 Transmission

Standard Transmission:

NV3550 5-speed Manual Transmission

Optional Transmission:

42RLE 4-speed Automatic Transmission

Transfer Case:

NV241OR 'Rubicon' (typically on Rubicon trims) or NV231 Command-Trac part-time, single-speed (non-Rubicon) or dual-range transfer case

Clutch Type:

Hydraulic-actuated dry single plate clutch (for manual transmission)

Transmission Fluid Spec:

Mopar Manual Transmission Lubricant (or equivalent, e.g., GL-3/GL-4 75W-90)

Transmission Fluid Spec:

Chrysler ATF+4 (MS-9602)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

159.3 inches (4046 mm)

Width:

66.7 inches (1694 mm)

Height:

70.5 inches (1791 mm) (with soft top)

Seating Capacity:

4

Volume Behind Rear Seat:

39.7 cu ft (1.12 m³)

Volume Total:

75.1 cu ft (2.13 m³)

Curb Weight:

Approx. 3,300-3,500 lbs (1,497-1,588 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 4,500 lbs (2,041 kg)

🛡️ Safety Features

NHTSA Front Impact:

4 Stars (Driver), 4 Stars (Passenger)

NHTSA Side Impact:

4 Stars (Front Passenger), 3 Stars (Rear Passenger)

IIHS Moderate Overlap Frontal:

Good

Active Features:

Anti-lock Braking System (ABS) on front discs and rear drums, Optional Traction Control System (TCS) on some models.

Passive Features:

Seat belts (front and rear), Front airbags (driver and passenger), Roll bar/sport cage structure.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo with CD player (optional), optional Infinity sound system with amplifier and subwoofer. No integrated navigation or touchscreens typical of modern vehicles.

Driver Assistance Features:

Limited; primarily ABS on brakes. No electronic stability control or advanced driver-assistance systems (ADAS) such as adaptive cruise control or lane keeping assist.

Connectivity Features:

Basic; typically an auxiliary input for aftermarket audio devices. No Bluetooth or USB connectivity in factory configuration.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions and oil type used.

Transmission Fluid Interval:

Manual: Check at 30,000 miles, change as needed; Automatic: 30,000-60,000 miles (depending on driving severity).

Coolant Interval:

Every 30,000 miles or 2 years for conventional coolant; 100,000 miles or 5 years for extended life coolant (if used).

Engine Oil Specification:

SAE 10W-30 API SG or higher for 4.0L; SAE 5W-30 API SJ or higher for 2.4L

Coolant Specification:

Mopar Antifreeze/Coolant (MS-7170, typically a green ethylene glycol-based coolant)

Brake Fluid Specification:

DOT 3

Power Steering Fluid Specification:

ATF+4 (for 4.0L) or specific Mopar power steering fluid

Known Issues:

Cracked cylinder heads (common on early 4.0L engines, though less prevalent in later years like 2005), death wobble (steering instability at speed, often due to worn steering/suspension components), rust (especially on frames, body tub, and rocker panels), starter motor issues, front axle U-joint wear, leaky radiators, catalytic converter issues.

Oil Filter Part Number:

Mopar: MO-899 (4.0L); MO-349 (2.4L) (Note: Aftermarket equivalents are plentiful)

Air Filter Part Number:

Mopar: 53004396 (4.0L); 52104100 (2.4L) (Note: Aftermarket equivalents are plentiful)

📚 Vehicle History

Brand Heritage:

Jeep's lineage traces back to World War II, with a legacy built on ruggedness and off-road capability. The Wrangler is the direct descendant of the original Willys MB Jeep.

Model Evolution:

The TJ generation, produced from 1997 to 2006, marked a significant evolution with the introduction of coil springs, vastly improving ride comfort and articulation compared to the YJ's leaf springs. The 2005 model year features minor refinements and updates within the TJ's lifecycle.

Production Years:

1997-2006

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions:

The Jeep Wrangler TJ has consistently been recognized for its off-road capability. While specific awards for the 2005 model year are general to the TJ generation, it's frequently cited in 'best off-road vehicle' lists and publications.

Ratings:

Consumer satisfaction ratings often highlight its off-road performance and iconic design, while acknowledging typical vehicle issues for its age and class.

Certifications:

Standard EPA emissions certifications for the model year.