2004 Jeep Wrangler Service Repair Manual 04

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV, Off-Road Vehicle Target Audience: Off-road enthusiasts, Jeep owners seeking...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV, Off-Road Vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking DIY maintenance and repair

Competitive Analysis

Competitors 2004:

Toyota Tacoma, Nissan Xterra, Suzuki Vitara, Hummer H2 (though less direct)

Key Features Vehicle

Off Road Capability:

Solid axles, high ground clearance, available locking differentials, robust 4x4 system

Design:

Iconic Jeep styling, removable doors and top, utilitarian interior

Manual Value Proposition

Completeness:

The most comprehensive service manual available for the 2004 Jeep Wrangler, covering all factory procedures and specifications.

📋 Manual Details

Coverage Areas

General Coverage:

Complete Service and Repair Information

Specific Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body, Emissions

Page Count

Estimated Pages:

Thousands (digital format allows for extensive detail)

Manual Type

Type:

Factory Authorized Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, connecting rods, crankshaft, lubrication system, cooling system, timing system

Engine Electrical:

Ignition system, fuel injection system, starting system, charging system, engine control module (ECM) diagnosis and wiring diagrams

Transmission Manual:

NV1500, NV3550 clutch system, internal components, removal and installation, fluid specifications

Transmission Automatic:

42RLE removal and installation, torque converter, internal components, fluid specifications, diagnostic procedures

Drivetrain:

Transfer case (NV241DHD, NV231), front and rear axles (Dana 30, Dana 35), driveshafts, U-joints, differential service

Suspension:

Front coil spring suspension, rear multi-link coil spring suspension, shock absorbers, springs, control arms, sway bars

Steering:

Power steering system, steering gear, steering column, steering linkage, alignment specifications

Brakes:

Front disc brakes, rear drum brakes, ABS system, hydraulic lines, master cylinder, brake booster, parking brake

Electrical System:

Battery, charging system, lighting system, instrument cluster, power distribution, fuses, relays, body control module (BCM), wiring diagrams for all circuits

HVAC:

Air conditioning system, heater system, blower motor, controls, refrigerant charging, component replacement

Body:

Body panels, doors, hood, tailgate, bumpers, interior trim, seats, convertible top, hardtop service

Emissions Control:

Evaporative emission control (EVAP) system, exhaust system, catalytic converter, oxygen sensors, diagnostic trouble codes (DTCs)

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes, tune-ups, spark plug replacement, belt inspection and replacement

Diagnostic Procedures:

Troubleshooting guides for common issues, diagnostic trouble code (DTC) interpretation, electrical circuit testing, component testing

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems

Overhaul Procedures:

Complete engine and transmission overhaul instructions, including specifications and tolerances

Special Tools:

Identification and usage of specific tools required for certain repairs and diagnostics

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds

Detail Level:

Includes detailed torque specifications, clearances, diagnostic procedures, and wiring diagrams

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval

Print Quality

Quality:

High-resolution scans of original factory manuals, ensuring clear text and diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

2.4L (ED1)

Engine Type:

Inline 4-cylinder

Displacement:

2378 cc (145 cu in)

Bore X Stroke:

92.0 mm x 88.0 mm (3.62 in x 3.46 in)

Compression Ratio:

9.8:1

Horsepower:

147 hp @ 5200 rpm

Torque:

190 lb-ft @ 3200 rpm

Secondary Engine

Engine Code:

4.0L (ERH, ERT)

Engine Type:

Inline 6-cylinder, OHV, Pushrod

Displacement:

3956 cc (242 cu in)

Bore X Stroke:

98.5 mm x 86.6 mm (3.88 in x 3.41 in)

Compression Ratio:

8.8:1

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Pump Pressure:

39-46 psi (2.7-3.2 bar)

Lubrication

Oil Capacity 4.0L:

5 US quarts (4.7 liters) with filter

Oil Capacity 2.4L:

4.5 US quarts (4.3 liters) with filter

Cooling

Coolant Capacity:

10.5 US quarts (9.9 liters) for 4.0L, 8.1 US quarts (7.7 liters) for 2.4L

🔧 Transmission

Standard Transmission

Type 4Cyl:

NSG370 (6-speed manual)

Type 6Cyl:

NV3550 (5-speed manual)

Optional Transmission

Type 4Cyl Optional:

42RLE (4-speed automatic)

Type 6Cyl Optional:

42RLE (4-speed automatic)

Features

Manual Clutch Fluid:

DOT 3 Brake Fluid

Automatic Fluid Type:

ATF+4 (Mopar)

Manual Transmission Fluid:

NV3550: Mopar Manual Transmission Lubricant (or equivalent) / NSG370: SAE 75W-90 Synthetic Gear Oil

Transfer Case Fluid:

NV241DHD/NV231: ATF+4 (Mopar) or equivalent

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

158.5 inches (4026 mm)

Width Body:

66.5 inches (1689 mm)

Height:

70.5 inches (1791 mm)

Ground Clearance:

approx. 10.2 inches (259 mm)

Weights

Curb Weight Approx:

3500-3700 lbs (1588-1678 kg)

Gross Vehicle Weight Rating Gvwr:

4400-4600 lbs (1996-2087 kg)

Cargo

Cargo Volume Behind Rear Seat:

30.4 cu ft (0.86 m³)

Cargo Volume Max:

62.7 cu ft (1.78 m³)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3/5 stars (may vary by configuration)

Active Features

Available Anti-lock Braking System (ABS)

Four Wheel Drive:

Command-Trac (2-speed transfer case) or optional Select-Trac (full-time 4WD)

Passive Features

Airbags:

Driver and passenger front airbags

Seatbelts:

Three-point front seat belts, two-point rear seat belts

💡 Technology Features

Infotainment

Audio System Options:

Factory AM/FM/CD player, optional Infinity speaker system

Connectivity:

Limited in 2004 models; typically no Bluetooth or advanced connectivity features. Auxiliary input may be present on some aftermarket or later factory units.

Driver Assistance

Cruise Control:

Available

Traction Control:

N/A (Traction Control System was not typically offered)

Powertrain Control

Engine Control Module:

PCM (Powertrain Control Module) manages engine and transmission functions. Diagnostic connectors (OBD-II) are present for fault code retrieval.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions.

Transmission Fluid Change Interval:

Automatic: 30,000-60,000 miles (48,000-96,000 km) or every 2-4 years. Manual: Inspect as needed, typically every 60,000 miles (96,000 km).

Transfer Case Fluid Change Interval:

Every 30,000-60,000 miles (48,000-96,000 km)

Differential Fluid Change Interval:

Every 30,000-60,000 miles (48,000-96,000 km), especially if used for off-roading.

Engine Coolant Change Interval:

Every 30,000 miles (48,000 km) or 2 years.

Fluid Specifications

Engine Oil Spec 4.0L:

API SN, SAE 10W-30 (check owner's manual for specific viscosity based on climate)

Engine Oil Spec 2.4L:

API SN, SAE 5W-30 (check owner's manual for specific viscosity based on climate)

Brake Fluid Spec:

DOT 3

Known Issues

Common Problem 1:

Cracked exhaust manifolds (especially 4.0L) due to heat cycling.

Common Problem 2:

Worn steering box and tie rod ends leading to steering looseness.

Common Problem 3:

Leaks from the transfer case or transmission seals.

Common Problem 4:

Radiator failures or leaks.

Common Problem 5:

Death wobble (violent oscillation of the front end, often related to steering and suspension components).

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long and storied history of producing rugged, off-road capable vehicles dating back to World War II with the Willys MB.

Model Evolution

Wrangler Lineage:

The Wrangler (YJ, TJ, JK, JL) is the spiritual successor to the CJ (Civilian Jeep) series, maintaining its iconic design and off-road prowess.

Tj Generation Start:

The TJ generation was introduced for the 1997 model year.

Tj Generation End:

The TJ generation concluded with the 2006 model year.

Production

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized by off-road enthusiasts and publications for its exceptional trail capability. Often cited as a benchmark for factory off-road performance.