Vehicle Segment:
Compact Sport Utility Vehicle (SUV) / Off-road Vehicle
Target Audience:
Off-road enthusiasts, Jeep owners, DIY mechanics, professional technicians
Competitors:
Toyota Tacoma, Nissan Frontier, Ford Bronco (earlier generations)
Vehicle Philosophy:
Ruggedness, off-road capability, open-air driving experience, iconic design
Manual Value Proposition:
Empowers owners and technicians with comprehensive, accurate repair and maintenance data for the TJ Wrangler, facilitating cost-effective upkeep and problem-solving.
Manufacturers Covered:
Jeep
Models Covered:
Wrangler TJ
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Estimated Page Count:
Thousands (typically >2000 for complete workshop manuals of this scope)
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management
Transmission Drivetrain:
Manual transmission, automatic transmission, transfer case, drivelines, axles, differentials
Suspension Steering:
Front and rear suspension (coil spring design), steering system, power steering
Brakes:
Front and rear brakes (disc/drum configurations), anti-lock braking system (ABS) if equipped, parking brake
Electrical Electronics:
Battery, charging system, starting system, lighting, instrumentation, body control modules, wiring diagrams, fuses, relays
Body Chassis:
Body panels, doors, interior trim, seats, glass, bumpers, frame, exhaust system
HVAC:
Heating, ventilation, and air conditioning (HVAC) system
Safety Restraint:
Airbags, seat belts
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication
Repair:
Component removal, installation, and repair for all major systems
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting
Rebuilds:
Detailed engine, transmission, and transfer case rebuild procedures
Adjustments:
Wheel alignment, brake adjustments, clutch adjustments
Technical Specifications:
Torque specifications, clearances, tolerances, specifications for all components
Depth:
Comprehensive (covers routine maintenance to complete overhauls and complex diagnostics)
Diagnostic Tools:
Includes information on diagnostic connectors and procedures, likely referencing OBD-II (On-Board Diagnostics II) for applicable years.
Digital Format:
PDF (Portable Document Format)
Searchability:
Typically searchable text, allowing for quick navigation to specific topics.
Print Capability:
Printable pages for physical reference.
Binding:
N/A (Digital Format - if printed, typically comb or spiral bound for ease of use in a workshop environment)
Paper Quality:
N/A (Digital Format - if printed, typically high-quality paper suitable for workshop use)
Engine Family:
Chrysler/Jeep AMC Straight-6 OHV
Engine Displacement 1:
4.0L (242 cu in)
Horsepower 1:
Approx. 181-190 hp (depending on year)
Torque 1:
Approx. 220-235 lb-ft (depending on year)
Fuel System 1:
Electronic Multi-Point Fuel Injection (MPI)
Engine Displacement 2:
2.5L (150 cu in) 4-Cylinder
Horsepower 2:
Approx. 117-121 hp
Torque 2:
Approx. 135-140 lb-ft
Fuel System 2:
Electronic Multi-Point Fuel Injection (MPI)
Engine Orientation:
Inline
Engine Configuration:
OHV (Overhead Valve) for 4.0L, OHV for 2.5L
Type 1:
Manual Transmission
Models 1:
AX-5 (2.5L), NV3550 (4.0L late models)
Type 2:
Automatic Transmission
Models 2:
AW4 (early 4.0L), 32RH (later 4.0L)
Gears 2:
3-speed or 4-speed (depending on model)
Transfer Case:
NP231 (Command-Trac) - Part-time, 2-speed, manual shift
Wheelbase Short:
93.4 inches (2372 mm)
Wheelbase Long:
104.4 inches (2652 mm) - Unlimited model
Length Short:
151.3 inches (3843 mm)
Length Long:
164.1 inches (4168 mm) - Unlimited model
Width:
66.7 inches (1694 mm)
Height:
71.0 inches (1803 mm)
Curb Weight Min:
Approx. 3,200 lbs (1451 kg)
Curb Weight Max:
Approx. 3,700 lbs (1678 kg)
NHTSA Front Crash:
Likely 4-star (specific ratings may vary by year and testing methodology)
IIHS Ratings:
Varies by year; often good to acceptable in frontal impact tests.
ABS:
Available on front disc brakes, optional on rear drum brakes (depending on year and trim)
Traction Control:
Optional on some later models.
Airbags:
Driver and passenger front airbags (standard)
Seatbelts:
Three-point seat belts with pretensioners
Audio System:
Basic AM/FM radio, CD player (optional), premium sound systems available on higher trims.
Display:
Analog gauges, basic digital odometer. No central infotainment screen in most models.
Auxiliary Input:
Generally not standard; aftermarket solutions common.
Oil Change Interval:
Every 3,000 - 5,000 miles (10W-30 or 5W-30 conventional/synthetic, depending on climate and engine)
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 100,000 miles (depending on plug type, e.g., copper vs. platinum/iridium)
Coolant Flush:
Every 30,000 - 50,000 miles or 2-5 years (use Mopar OAT or HOAT coolant).
Engine Oil Type:
API Certified SAE 10W-30 (4.0L) or SAE 5W-30 (2.5L and some 4.0L) - check owner's manual for specific recommendations.
Transmission Fluid Manual:
GL-3 or GL-4 rated gear oil (e.g., Pennzoil Synchromesh, Red Line MT-90)
Transmission Fluid Automatic:
ATF+4 (Mopar Genuine)
Transfer Case Fluid:
ATF+4 (Mopar Genuine) or equivalent
Common Problems Engine:
Oil filter housing leaks, cracked exhaust manifolds (4.0L), camshaft position sensor issues.
Common Problems Transmission:
Clutch wear, input shaft seal leaks (manual), torque converter issues (automatic).
Common Problems Suspension Steering:
Worn track bar bushings, ball joint wear, steering stabilizer failure, death wobble (can be related to various worn components).
Common Problems Body Chassis:
Frame rust (especially rear), tub rust, door seal leaks, cowl panel leaks.
Common Problems Electrical:
Alternator failure, PDC (Power Distribution Center) issues, instrument cluster problems.
Jeep Legacy:
Direct descendant of the Willys MB military Jeep, renowned for off-road prowess since WWII.
Tj Introduction:
Introduced for the 1997 model year, replacing the YJ generation. Marked a significant departure with coil spring suspension.
Tj Key Changes:
Shift from leaf springs to coil springs, round headlights return, improved interior ergonomics, revised chassis.
Manufacturing Location:
Toledo, Ohio, USA
Production Years:
1996 (early models) - 2006
