🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation Code:

TJ

Model Year:

2004

👋 Introduction

Positioning:

The Jeep TJ Wrangler is an iconic off-road vehicle, known for its capability and ruggedness. This manual caters to owners and technicians who perform their own maintenance and repairs.

Competitors:

While direct competitors in the compact SUV segment existed, the TJ Wrangler stood apart with its off-road focus, appealing to a niche market. This manual provides the in-depth technical data needed to maintain its unique capabilities.

Manual Value:

Provides factory-level repair procedures, diagnostic information, and specifications essential for the 2004 TJ Wrangler.

Vehicle Focus:

Emphasizes the specific engineering and design elements that make the TJ Wrangler a distinct and capable vehicle.

📋 Manual Details

Engine Coverage:

All 2004 TJ Wrangler engine variants

Transmission Coverage:

All 2004 TJ Wrangler transmission variants (manual and automatic)

Chassis Coverage:

Frame, suspension, steering, axles, brakes

Electrical Coverage:

Wiring diagrams, electrical component testing, lighting, accessories

Body Coverage:

Body panels, interior trim, convertible top, doors, bumpers

HVAC Coverage:

Heating, ventilation, and air conditioning systems

Diagnostics Coverage:

Troubleshooting guides, diagnostic trouble codes (DTCs)

Total Pages:

2436

Type:

Factory Authorized Service Manual

Language:

English

Format:

Print

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, engine management

Drivetrain:

Transfer case, front axle, rear axle, driveshafts, differentials

Suspension Steering:

Front and rear suspension components, steering gear, power steering system

Brakes:

Front and rear brake systems (disc/drum configurations), ABS (if equipped), parking brake

Wheels Tires:

Wheel specifications, tire pressures, rotation

Body Structure:

Body construction, frame rails, chassis components

Comfort Convenience:

Seats, interior trim, door mechanisms, power windows, locks, mirrors

Lighting Signals:

Headlights, taillights, turn signals, interior lighting

Restraints:

Seat belts, airbags (system description and basic checks)

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication

Component Replacement:

Engine components, transmission removal/installation, suspension parts, brake components, exhaust system

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and complex issues

Rebuilds Overhauls:

Detailed instructions for engine, transmission, and axle rebuilds

Electrical Diagnostics:

Testing of sensors, actuators, modules, wiring harness troubleshooting

Body Repair:

Panel alignment, rust repair guidance, convertible top maintenance

HVAC Service:

Refrigerant handling, component replacement, system diagnostics

Depth:

Comprehensive, from basic maintenance to complete factory-level overhauls

Diagnostic Tools:

Information on using scan tools and specific diagnostic procedures

Special Tools:

Identification of Chrysler/Jeep specific tools required for certain procedures

📊 Manual Specifications

Format:

Printed Book

Quality:

High-quality, durable paper stock suitable for shop environments

Binding:

Spiral-bound or perfect-bound for lay-flat usability

Paper:

Heavy-duty, smudge-resistant paper

⚙️ Engine Specifications

Engine Name:

Chrysler 4.0L Inline-6 'Power Tech'

Engine Displacement:

3952 cc (241 cubic inches)

Engine Configuration:

Inline 6-cylinder, Overhead Valve (OHV)

Bore X Stroke:

93.1 mm x 91.9 mm (3.66 in x 3.62 in)

Compression Ratio:

8.8:1

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Horsepower @ Rpm:

190 hp @ 4,600 rpm

Torque @ Rpm:

235 lb-ft @ 3,200 rpm

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Fuel Tank Capacity:

19.0 US gallons (71.9 L)

Coolant Type:

Mopar Antifreeze/Coolant (50/50 mix with distilled water)

Spark Plugs:

Champion Copper Plus (e.g., RC12LYC) or equivalent

🔧 Transmission

Transmission Type 1:

NV3550 5-speed Manual Transmission

Transmission Type 2:

42RLE 4-speed Automatic Transmission

Manual Fluid Type:

NV3550: Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4 75W-90)

Automatic Fluid Type:

42RLE: ATF+4 (Mopar P/N 05013457AA or equivalent)

Transfer Case Model:

NV241OR 'Rock-Trac' (standard for Rubicon, optional elsewhere)

Transfer Case Fluid:

Mopar ATF+4 (or equivalent)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Overall Length:

151.4 inches (3845 mm)

Overall Width:

66.5 inches (1689 mm)

Overall Height:

73.5 inches (1867 mm)

Ground Clearance:

10.1 inches (257 mm) (Rubicon, with specified tires)

Curb Weight Est:

3,500 - 4,000 lbs (1588 - 1814 kg) depending on configuration

Gross Vehicle Weight Rating Gvw:

4,800 lbs (2177 kg)

🛡️ Safety Features

NHTSA Rollover Resistance:

Four-star rating (for 2004 models)

ABS:

Available (standard on Rubicon, optional on others)

Airbags:

Driver and passenger front airbags

Seat Belts:

3-point front seat belts, 2-point rear seat belts (early models) / 3-point rear (later TJ models)

💡 Technology Features

Audio System:

Optional AM/FM stereo with CD player, cassette player, and premium speaker options.

Climate Control:

Manual climate control with standard A/C and heating.

Cruise Control:

Available

Connectivity Options:

Limited by modern standards; primarily features auxiliary input for aftermarket audio devices.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months (severe service) / 5,000 miles or 6 months (normal service)

Engine Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 100,000 miles (Champion Copper Plus)

Transmission Fluid Change Manual:

Inspect at 30,000 miles; replace as needed or at 60,000 miles.

Transmission Fluid Change Automatic:

Inspect at 30,000 miles; change fluid and filter at 60,000 miles (or sooner under severe use).

Transfer Case Fluid Change:

Inspect at 30,000 miles; change at 60,000 miles.

Brake Fluid Flush:

Every 30,000 miles or 24 months

Engine Oil Capacity:

6.0 US quarts (5.7 L) with filter, for 4.0L I6 (check manual for exact capacity)

Engine Oil Viscosity:

10W-30 (API SJ or higher)

Power Steering Fluid:

ATF+3 or ATF+4 (Mopar P/N 05013457AA or equivalent)

Coolant Capacity:

Approximately 11.0 US quarts (10.4 L) (4.0L engine)

Common Issues Engine:

Cracked cylinder heads (early 4.0L engines, less common in later years), oil filter adapter housing leaks, rear main seal leaks.

Common Issues Transmission:

NV3550: Synchronizer wear, clutch issues. 42RLE: Torque converter shudder, solenoid failures.

Common Issues Suspension Steering:

Worn control arm bushings, ball joint wear, steering box play, track bar wear.

Common Issues Electrical:

Intermittent instrument cluster issues, headlight switch failures, ground point corrosion.

Common Issues Body:

Door hinge rust, tailgate hinge rust, floor pan rust, soft top seal leaks.

📚 Vehicle History

Jeep Legacy:

The Jeep Wrangler lineage traces back to the Willys MB Jeep of World War II, establishing a legacy of off-road prowess and ruggedness.

Tj Generation:

The TJ Wrangler, produced from 1997-2006, introduced coil spring suspension for improved on-road comfort and articulation compared to its leaf-sprung YJ predecessor. The 2004 model year saw minor updates, continuing the core TJ design.

Production Location:

Toledo, Ohio, USA

Model Years Produced:

1997-2006

🏆 Awards & Recognition

Offroad Capability Awards:

Consistently recognized by off-road publications and enthusiasts for its superior articulation, ground clearance, and four-wheel-drive systems.

Consumer Reports Reliability:

Varies by model year and specific components; often cited for mechanical robustness but with occasional electrical gremlins.

Safety Certifications:

Meets all applicable US Federal Motor Vehicle Safety Standards (FMVSS).