Vehicle Segment:
Compact SUV / Off-road vehicle
Target Audience:
Off-road enthusiasts, Jeep owners seeking reliable repair information
Key Competitors 2004:
Toyota Tacoma, Nissan Xterra, Ford Explorer Sport Trac
Vehicle Distinctiveness:
Iconic off-road capability, removable doors and top, solid front axle (pre-2007)
Manual Value Proposition:
Empowers owners to perform complex repairs and maintenance, saving on labor costs.
Engine Repair:
Detailed diagnosis, repair, and overhaul procedures for all engine options
Transmission Repair:
Service and repair for manual and automatic transmissions
Drivetrain Repair:
Axles, differentials, transfer case (NV241OR/NV241GHD), driveshafts
Suspension Repair:
Front and rear suspension, shock absorbers, springs, control arms, linkages
Brake System Repair:
Front and rear brake assemblies, ABS diagnostics and repair
Steering System Repair:
Power steering system, steering gear, steering column
Electrical System Repair:
Battery, charging system, starting system, lighting, ignition, wiring diagrams
HVAC System Repair:
Heating, ventilation, and air conditioning system diagnosis and repair
Body And Chassis Repair:
Frame, body panels, doors, seats, interior trim, convertible top
Emissions Control System:
Diagnosis and repair of emissions components and systems
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotations
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides
Component Removal And Installation:
Step-by-step instructions for component R&I
Rebuilding Procedures:
Detailed procedures for engine, transmission, and axle rebuilding
Torque Specifications:
Critical torque values for fasteners across all systems
Wiring Diagrams:
Comprehensive electrical schematics with component identification
Depth Level:
Factory-level detail, suitable for professional technicians and advanced DIYers
Diagnostic Procedures:
In-depth diagnostic strategies, including scan tool data interpretation
Special Tools:
Identification and usage instructions for specialized service tools
Engine Type Standard:
4.0L (242 cu in) Inline-6, Overhead Valve (OHV), Pushrod
Engine Displacement Liters:
4.0
Engine Configuration:
Inline-6
Bore X Stroke:
3.875 in x 3.414 in (98.4 mm x 86.7 mm)
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Horsepower Net Hp:
190 hp @ 4600 rpm
Torque Net Lb-Ft:
235 lb-ft @ 3200 rpm
Ignition System:
Distributorless Ignition System (DIS)
Cooling System:
Pressurized, coolant-cooled
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity Gallons:
15.0
Transmission Type Standard:
AX-5 5-speed manual transmission
Transmission Type Optional:
42RLE 4-speed automatic transmission
Transfer Case:
NV241OR (4-Wheel Drive, Part-Time, 2-Speed)
Clutch Type:
Hydraulically actuated, single dry plate (manual)
NHTSA Frontal Crash Driver:
4 Stars
NHTSA Frontal Crash Passenger:
4 Stars
NHTSA Side Impact Front Driver:
5 Stars
NHTSA Side Impact Front Passenger:
5 Stars
ABS:
Standard Anti-lock Braking System (ABS) - 4-wheel disc brakes
Traction Control:
Optional
Airbags:
Driver and front passenger airbags
Rollover Protection:
Sport cage integrated into body structure
Infotainment System:
Base AM/FM stereo with CD player; optional premium sound system
Speakers:
Standard 4 speakers; optional 6-speaker system
Driver Assistance Features:
Limited; primarily ABS
Connectivity Options:
Limited; often requires aftermarket upgrades for modern connectivity
Oil Change Interval:
Every 3,000-6,000 miles or 6 months (refer to manual for specific conditions)
Engine Coolant Flush:
Every 30,000-50,000 miles or 2-3 years
Transmission Fluid Change Auto:
Every 30,000-60,000 miles
Transmission Fluid Change Manual:
Every 30,000-60,000 miles
Engine Oil Type And Viscosity:
API certified SAE 10W-30 (preferred), SAE 5W-30 in extreme cold
Engine Oil Capacity Quarts:
5.0 (with filter)
Coolant Type:
Chrysler OAT (Orange) Antifreeze/Coolant, 50/50 mixture with distilled water
Automatic Transmission Fluid Type:
ATF+4 (MS-9602)
Manual Transmission Fluid Type:
MS-9224 (90W GL-3 or GL-4 for AX-5, 75W-90 GL-4 for NV3550/NVC-145, refer to manual for exact specs)
Power Steering Fluid Type:
ATF+4
Common Wear Item Clutch:
Clutch wear and failure in manual transmissions
Common Wear Item Suspension:
Wear in control arm bushings, track bar bushings, and ball joints due to off-road use.
Common Engine Issue Ticking:
"Ticking" noise from the 4.0L engine due to lifter noise, often exacerbated by oil type/level.
Common Electrical Issue Wiring:
Corrosion in electrical connectors, especially for exterior lighting and trailer wiring.
Jeep Legacy:
Direct descendant of WWII Willys MB, synonymous with off-road capability
Tj Generation Period:
1997-2006
Tj Key Advancement:
Return to coil springs and the iconic round headlights, reintroduction of the solid front axle.
Production Plant:
Toledo South Assembly Plant, Toledo, Ohio
