Positioning:
Essential resource for Jeep Wrangler TJ owners and independent repair shops seeking professional-level service information.
Comparison:
Surpasses aftermarket Haynes/Chilton manuals in detail and accuracy, offering factory-level insights identical to those used by Jeep dealerships.
Feature 1:
Unparalleled comprehensiveness for TJ model years 1996-2006.
Feature 2:
Detailed, illustrated step-by-step procedures for virtually every repair and maintenance task.
Feature 3:
Includes diagnostic procedures and electrical schematics crucial for modern vehicle repair.
Engine Systems:
Engine mechanical (including teardown and reassembly), fuel system, ignition system, cooling system, lubrication system, emission control systems.
Drivetrain Systems:
Manual transmission (AX-5, NV3550), automatic transmission (42RLE), transfer case (NV231, NV241OR), front and rear axles (Dana 30, Dana 35c, Dana 44), driveshafts, differentials, hub assemblies.
Suspension Steering:
Front and rear suspension components (leaf springs, coil springs, control arms, shocks, sway bars), steering gear, power steering system, wheel alignment specifications.
Brakes Systems:
Front and rear brake systems (disc and drum), ABS system, parking brake, hydraulic system components, bleeding procedures.
Electrical Systems:
Wiring diagrams, starter, alternator, battery, lighting systems, power windows, power locks, instrument cluster, diagnostic trouble codes (DTCs), Body Control Module (BCM) related functions.
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, diagnostics.
Body Chassis:
Body panel removal and installation, interior trim, doors, hoods, tailgates, frame specifications, collision repair information.
Maintenance Procedures:
Routine maintenance checks, fluid changes, filter replacements, spark plug replacement, belt inspection and replacement, brake pad replacement.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation and resolution, multimeter usage for electrical diagnostics.
Repair Procedures:
Step-by-step repair instructions for all major mechanical and electrical components, including engine overhaul, transmission rebuilds, brake caliper replacement, axle seal replacement, driveline component repair.
Installation Procedures:
Installation of new or replacement parts, accessory installation guidelines where applicable.
Depth:
Comprehensive from basic maintenance to complete vehicle teardown and rebuild.
Detail Level:
Detailed, step-by-step instructions with high-quality diagrams and illustrations.
Torque Specs:
Includes all critical torque specifications for fasteners across all systems.
Wiring Diagrams:
Full color, detailed electrical wiring diagrams for all vehicle systems.
Transmission Type Standard:
5-speed manual (AX-5 for 2.4L, NV3550 for 4.0L)
Transmission Type Optional:
4-speed automatic (42RLE)
Transfer Case Options:
New Venture Gear NV231 (Command-Trac 2-speed) or NV241OR (Rock-Trac 4-speed)
Clutch Type:
Dry single plate (manual transmission)
Wheelbase 2-Door:
93.4 inches (2372 mm)
Wheelbase 4-Door Unlimited:
103.4 inches (2626 mm)
Length 2-Door:
151.4 inches (3845 mm)
Width Body:
73.1 inches (1857 mm)
Height Overall:
72.9 inches (1852 mm)
Curb Weight Approx:
3,500 - 4,000 lbs (1588 - 1814 kg)
Gross Vehicle Weight Rating Gvwr:
4,750 - 5,250 lbs (2155 - 2381 kg)
Cargo Volume Behind Rear Seat:
38.7 cu ft (1096 L)
Cargo Volume With Rear Seat Folded:
71.0 cu ft (2010 L)
NHTSA Rollover Resistance:
4/5 Stars (Varies by model year and configuration)
Braking System:
Standard front disc brakes, rear drum brakes; optional ABS (Anti-lock Braking System).
Traction Control:
Available on some later models.
Airbags:
Driver and passenger front airbags.
Seat Belts:
Three-point front seat belts, lap belts for rear passengers (depending on configuration).
Rollover Protection:
Integral sport bar and roll cage structure.
Oil Change Interval:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, depending on oil type and driving conditions.
Engine Coolant Interval:
Initial change at 5 years/100,000 miles (160,000 km), then every 2 years/30,000 miles (48,000 km).
Spark Plug Interval:
Approx. 100,000 miles (160,000 km) for Platinum or Iridium plugs; check specific type. Copper plugs require more frequent changes.
Engine Oil Type 4.0L:
SAE 10W-30 API SG or higher (check owner's manual for updated specs).
Engine Oil Type 2.4L:
SAE 5W-30 API SG or higher (check owner's manual for updated specs).
Coolant Type:
Chrysler/Jeep HOAT (Hybrid Organic Acid Technology) coolant, typically orange or Mopar OAT.
Transmission Fluid Manual Nv3550:
API GL-3 or GL-4, SAE 75W-90 Gear Oil (e.g., Mopar Manual Transmission Lubricant, Pennzoil Synchromesh).
Transmission Fluid Automatic 42Rle:
ATF+4 (Automatic Transmission Fluid type 9602 or equivalent).
Transfer Case Fluid:
ATF+4 (Automatic Transmission Fluid type 9602 or equivalent).
Axle Differential Fluid:
API GL-5, SAE 75W-90 or 75W-140 Synthetic Gear Lubricant. Add friction modifier for limited-slip differentials if equipped.
Common Issue 1:
4.0L Head Gasket Failure: Particularly common in earlier 4.0L engines, often exacerbated by overheating.
Common Issue 2:
Oil Filter Adapter Gasket Leak: A common source of oil leaks on the 4.0L engine.
Common Issue 3:
Radiator and Cooling System Issues: Overheating can lead to head gasket failure, so regular coolant checks and radiator condition are vital.
Common Issue 4:
Rear Main Seal Leak: A frequent leak point on both 4.0L and 2.4L engines.
Common Issue 5:
Brake Wear: Due to its off-road nature, brake components may wear more rapidly under heavy use.
Common Issue 6:
Manual Transmission Bearing Noise: Some NV3550 transmissions can develop bearing noise over time.
Jeep Legacy:
Continuation of the Jeep lineage, tracing roots back to WWII military vehicles and the original CJ series.
Tj Introduction:
The TJ Wrangler replaced the YJ Wrangler in 1996 for the 1997 model year. Key innovations included a return to round headlights and a significant redesign of the suspension system.
Tj Suspension Upgrade:
Introduction of coil springs on all four corners, a major departure from the YJ's leaf springs, providing improved on-road ride and off-road articulation.
Tj Unlimited Variant:
Introduction of the Wrangler Unlimited (LJ) in 2004, featuring a stretched wheelbase for increased interior and cargo space.
Production Period:
1996 (for 1997 model year) to 2006.
Key Manufacturing Location:
Toledo, Ohio, USA.
