Jeep Wrangler TJ 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Generation Generation Designation: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-road vehicle Usp: Renowned...

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Sku: 448310

Tags: 2004 Car Cars Jeep Misc Wrangler TJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Generation

Generation Designation:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-road vehicle

Renowned for its off-road capability, rugged design, and open-air experience

Competitive Analysis

Competitors 2004:

Toyota Tacoma (less focused on off-road), Toyota 4Runner, Land Rover Defender (discontinued in US market), Suzuki Samurai (older model, less refined)

Key Features

Design Philosophy:

Body-on-frame construction, solid front and rear axles (a key differentiator), removable doors and roof

Target Audience:

Off-road enthusiasts, adventure seekers, off-road vehicle purists

📋 Manual Details

Coverage Areas

Engine Coverage:

All engines and variants

Transmission Coverage:

Manual and Automatic Transmissions

Chassis Suspension Steering Coverage:

Comprehensive coverage of suspension, steering, and drivetrain components

Electrical System Coverage:

Detailed electrical system diagrams, component testing, and troubleshooting

Body And Interior Coverage:

Bodywork, interior trim, HVAC, and safety systems

Page Count

Estimated Page Count:

Over 1500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (likely PDF or similar digital format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, assembly, disassembly, cooling system, lubrication system, fuel delivery

Engine Performance:

Ignition system, emissions control, engine diagnostics

Transmission Manual:

Manual transmission removal, installation, and overhaul

Transmission Automatic:

Automatic transmission removal, installation, and overhaul

Transfer Case:

Transfer case service, repair, and troubleshooting

Axles And Differentials:

Front and rear axle service, differential repair, and axle shaft replacement

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings

Steering:

Steering gear, power steering system, steering column, tie rods

Brakes:

Disc brake systems, brake fluid, hydraulic lines, parking brake, ABS (if equipped)

Wheels And Tires:

Tire fitting, wheel balancing, wheel alignment procedures

Electrical Power Distribution:

Battery, charging system (alternator), starter motor

Lighting System:

Headlights, taillights, interior lighting, wiring diagrams

Instrumentation And Gauges:

Dashboard instruments, warning lights, sensor testing

Audio System:

Radio, speakers, antenna system

HVAC:

Heating, ventilation, and air conditioning system service and repair

Safety Restraints:

Seat belts, airbags (system diagnostics and replacement procedures if applicable)

Body Panels:

Doors, hood, fenders, tailgate, body sealing

Interior Trim:

Dashboard, door panels, seating, carpet replacement

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations

Troubleshooting Diagnostics:

Diagnostic trouble codes (DTCs), systematic fault finding, component testing

Component Rebuild:

Engine, transmission, transfer case, axle, and brake component rebuilds

Electrical Diagnostics:

Wiring harness tracing, component testing using multimeters and oscilloscopes

Body Repair:

Panel alignment, rust repair, dent removal, glass replacement

HVAC Service:

Refrigerant handling, component replacement (compressor, condenser, evaporator), leak detection

Wheel Alignment:

Alignment specifications and adjustment procedures

Torque Specifications:

Detailed torque values for all critical fasteners

Wiring Diagrams:

Comprehensive and detailed wiring schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive (covers basic maintenance to full engine and transmission rebuilds)

Diagnostic Tools:

Guidance on using diagnostic scan tools and multimeters

Special Tools:

Identification of required special tools for specific procedures

📊 Manual Specifications

File Format

Format:

PDF (searchable text, bookmarked sections, printable)

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Name:

4.0L Inline-6 (PowerTech)

Engine Code:

122 (Chrysler 4.0L)

Displacement Liters:

Cylinder Configuration:

Inline-6

Valve Train:

Overhead Valve (OHV) with Pushrods

Horsepower Hp:

190 @ 4600 RPM

Torque Lb Ft:

235 @ 3200 RPM

Bore X Stroke:

3.875 in x 3.530 in (98.4 mm x 89.7 mm)

Compression Ratio:

8.8:1

Fuel System

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Performance

0 60 Mph Seconds:

Approx. 9-10 seconds (varies with transmission and configuration)

🔧 Transmission

Standard

Transmission Type:

NV3550 5-Speed Manual

Optional

Transmission Type:

42RLE 4-Speed Automatic

Features

Transfer Case:

NP241J 'Rock-Trac' (Rubicon models) or NP231 'Command-Trac' (Sport/Sahara models)

Gear Ratios Manual:

First: 4.11, Second: 2.20, Third: 1.41, Fourth: 1.00, Fifth: 0.79 (approximate)

Gear Ratios Automatic:

First: 2.80, Second: 1.54, Third: 1.00, Fourth: 0.75 (approximate)

Fluid Type

Manual Transmission Fluid:

API GL-3 or GL-4 75W-90 Synthetic Gear Oil

Automatic Transmission Fluid:

ATF+4 (Mopar Material Number 05013457AA)

📐 Dimensions

Exterior

Wheelbase In:

Overall Length In:

155.4

Overall Width In:

Overall Height In:

Weights

Curb Weight Lbs:

Approx. 3,500 - 4,000 (depending on configuration)

Towing Capacity Lbs:

2,000

Payload Capacity Lbs:

Approx. 800-1000

🛡️ Safety Features

Ratings

NHTSA Rollover Rating 2004:

4/5 Stars (Driver and Passenger)

Active Features

Optional, typically on higher trims or later production

Traction Control:

Not typically equipped on this generation

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seat Belts:

3-point front and rear seat belts

💡 Technology Features

Infotainment

Audio System Options:

Base AM/FM radio, AM/FM with CD player, premium Infinity sound system

Navigation:

Not available from factory on 2004 models

Driver Assistance

Cruise Control:

Available on most trims

Anti Theft:

Factory immobilizer system

Connectivity

Auxiliary Input:

Not standard, some aftermarket units may include it

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (whichever comes first), or every 3,000 miles under severe driving conditions.

Engine Oil Filter Replacement:

With every oil change

Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 30,000 miles (recommended for optimal performance)

Coolant Flush Interval:

Every 30,000 miles or 24 months

Fluid Specifications

Engine Oil Capacity Quarts:

6.0 (with filter)

Engine Oil Type:

API SN/SN PLUS, ILSAC GF-5, SAE 10W-30 (check owner's manual for climate-specific recommendations)

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (MS-9769) or equivalent

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Chrysler Power Steering Fluid (MS-5901) or equivalent ATF+4

Known Issues

Common Problem 1:

Cracked exhaust manifolds (especially the 4.0L engine)

Common Problem 2:

Blend Door Actuator failure in HVAC system

Common Problem 3:

Leaks: Valve cover gasket, oil pan gasket, rear main seal

Common Problem 4:

Worn out control arm bushings and ball joints due to off-road use and age

Common Problem 5:

Transmission cooler lines can corrode and leak

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's legacy dates back to WWII Willys MB, known for off-road prowess and ruggedness

Model Evolution

Tj Generation Introduction:

The TJ generation was introduced for the 1997 model year, replacing the YJ. It marked a significant return to the iconic round headlights and coil spring suspension.

Tj Features Vs Yj:

Key improvements over the YJ included coil spring suspension (improved ride and articulation), a more modern interior, and the optional 4.0L inline-6 engine.

Production

Production Years:

1997-2006

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Popular Mechanics 2003 Award:

Car of the Year (for the TJ generation overall)

Off Road Magazine Ratings:

Consistently rated highly by off-road publications for its capability