🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Chassis Code:

TJ

Generation:

2nd Generation (TJ)

👋 Introduction

Positioning:

The 2004 Jeep Wrangler (TJ) is a highly capable off-road vehicle renowned for its iconic design and go-anywhere versatility. It occupies a niche segment focused on recreational off-roading and open-air driving experiences.

Competitors:

Competes with vehicles like the Toyota FJ Cruiser (later models), Land Rover Defender (in some markets), and custom-built off-road vehicles. Its direct competitors in its era were fewer due to its unique body-on-frame, solid axle configuration.

Features:

Iconic Wrangler styling, removable doors and top, solid front and rear axles, Command-Trac NV241 or optional Selec-Trac NV242 transfer case, robust off-road capability, high ground clearance, short wheelbase (for 2-door models).

📋 Manual Details

Primary Coverage:

Complete repair and service procedures for the 2004 Jeep Wrangler.

Scope:

Covers all mechanical, electrical, and body systems for the specified vehicle model year and generation.

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanical, cooling system, fuel system, exhaust system, transmission (manual & automatic), transfer case, driveline components (axles, differentials, driveshafts).

Chassis:

Suspension (front & rear), steering system, brake system (hydraulic, ABS), wheels, tires.

Electrical:

Battery, charging system, starting system, ignition system, lighting (headlamps, taillamps, interior), instrument cluster, power windows, power locks, horn, wipers/washers, audio/video systems, chime/buzzer, electronic control modules (ECMs, PCM, BCM), speed control, vehicle theft security system, wiring diagrams.

Body:

Body construction, doors, latches, hinges, glass, interior trim, exterior trim, bumpers, heating and air conditioning (HVAC), emission control systems.

Maintenance:

Routine maintenance schedules, fluid checks and changes, filter replacements, lubrication points, tire rotation, brake inspections.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension component upgrades, electrical diagnostics and component replacement.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, component testing procedures, wiring harness testing.

Special Tools:

Details on required special tools for specific repair procedures, often with part numbers.

Troubleshooting Flowcharts:

Includes diagnostic flowcharts for common electrical and mechanical issues.

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers diagnostics, component removal/installation, adjustments, specifications, and overhaul procedures.

Specifications:

Includes torque specifications for all fasteners, diagnostic parameters, electrical resistance values, and alignment specifications.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Searchability:

Likely searchable PDF text, allowing for quick finding of specific topics.

Quality:

High-resolution scans, clear text and diagrams, printable pages.

Binding:

Digital download, no physical binding.

Paper:

N/A (Digital)

⚙️ Engine Specifications

Engine Code:

e.g., 4.0L (High Output) - PowerTech I-6 (TJ 4.0L)

Displacement:

3952 cc (241 cubic inches)

Horsepower Max:

190 hp @ 4600 rpm (for 4.0L)

Torque Max:

235 lb-ft @ 3200 rpm (for 4.0L)

Injection Type:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Coolant Capacity Quarts:

11.1 quarts (10.5 liters) with heater

Coolant Type:

Chrysler (Mopar) OAT (Organic Acid Technology) Antifreeze/Coolant (Color: Pink) or equivalent.

Oil Capacity Quarts:

5.0 quarts (4.7 liters) with filter (for 4.0L)

Engine Oil Viscosity:

SAE 5W-30 (API certified)

Engine Code Secondary:

2.4L (EDZ) - PowerTech DOHC I-4 (Less common, often found in base models)

Horsepower I4:

147 hp @ 5200 rpm (for 2.4L)

Torque I4:

165 lb-ft @ 3800 rpm (for 2.4L)

🔧 Transmission

Type:

NV3550 5-speed Manual Transmission

Type:

42RLE 4-speed Automatic Transmission

Transfer Case Standard:

NV241 GII (Command-Trac 4x4)

Transfer Case Optional:

NV242 HD (Selec-Trac 4x4 - not common for 2004 TJ, but possible)

Fluid Type:

Manual Transmission Fluid (MTF), SAE 75W-90 GL-3 or GL-4

Atf Capacity Quarts:

Approximately 9.5 quarts (9.0 liters) for refill with filter change (42RLE)

Atf Type:

ATF+4 (Mopar)

Command Trac Low Range:

2.72:1

📐 Dimensions

Wheelbase Inches:

93.4 inches (2-Door)

Length Inches:

151.0 inches (2-Door)

Width Inches:

66.5 inches (Body)

Height Inches:

70.5 inches (with Hardtop)

Ground Clearance Inches:

Approx. 8.5 - 10 inches (depending on tire size and suspension)

Curb Weight Lbs:

3,400 - 3,700 lbs (approx. depending on configuration)

Gross Vehicle Weight Rating Gvwr Lbs:

4,500 - 4,600 lbs (approx.)

🛡️ Safety Features

NHTSA Driver Front Crash Rating:

4-star (for 2004 model year)

NHTSA Passenger Front Crash Rating:

4-star (for 2004 model year)

ABS:

Standard (Anti-lock Braking System)

Traction Control:

Optional on some models

Airbags:

Driver and Passenger Frontal Airbags

Seatbelts:

Three-point seat belts with pretensioners

💡 Technology Features

Audio System:

Basic AM/FM stereo with CD player, optional premium audio system with amplifier and subwoofer. Limited digital integration compared to modern vehicles.

Features:

Minimal driver assistance features by modern standards. Primarily relies on robust mechanicals for off-road performance.

Connectivity Options:

No Bluetooth or smartphone integration. Some models may have optional satellite radio.

🔧 Maintenance

Interval Miles:

Every 7,500 miles or 6 months, whichever comes first.

Air Filter Replacement:

Inspect every 15,000 miles; replace as needed.

Manual Transmission Fluid Change:

Inspect every 15,000 miles; change if contaminated or at higher mileage intervals (e.g., 60,000-100,000 miles).

Automatic Transmission Fluid Change:

Every 30,000 miles (severe duty/off-road use recommended).

Brake Fluid Type:

DOT 3 or DOT 4 (Mopar or equivalent)

Power Steering Fluid Type:

ATF+4 (Mopar) or equivalent

Common Problems:

Leaking valve cover gaskets, oil filter housing leaks, rear main seal leaks, transmission synchro issues (manual), AC evaporator core failures, exhaust manifold cracks (4.0L), sway bar disconnect issues (Rubicon models), rust on the body and frame (especially in certain climates).

Typical Repairs:

Valve cover gasket replacement, oil pan gasket replacement, AC system repair/recharge, clutch replacement, brake pad/rotor replacement, radiator replacement, sway bar link replacement.

Tire Rotation Interval:

Every 7,500 miles

📚 Vehicle History

Heritage:

Jeep has a long and storied history in off-road vehicle manufacturing, dating back to World War II with the original Willys Jeep. This heritage instills a strong brand identity centered around ruggedness and capability.

Tj Generation:

The TJ generation, introduced in 1997, marked a significant return to Jeep's roots by reintroducing the desirable coil-sprung solid front axle, a departure from the previous YJ's leaf springs. The 2004 model is part of the later TJ run, benefiting from refinements over previous years.

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Awards:

Consistently praised by off-road publications and enthusiasts for its capability and aftermarket support. Often ranked highly for its segment.