Jeep WRANGLER TJ 4X4 (LHD) 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Year: 2004 Drivetrain: 4x4 Steering Side: Left-Hand Drive (LHD) Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV/Off-road...

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标签: 2004 Car Cars Jeep Misc WRANGLER TJ 4X4 (LHD)

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Year:

Drivetrain:

Steering Side:

Left-Hand Drive (LHD)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV/Off-road Vehicle

Brand Perception:

Iconic off-road capability, ruggedness, and adventure.

Competitive Analysis

Direct Competitors:

Toyota Tacoma (as an off-road pickup), Nissan Xterra, Suzuki Vitara (earlier models), Land Rover Defender (historically).

Key Features

Design:

Classic Jeep design with removable doors, top, and fold-down windshield for maximum open-air experience.

Off Road Capability:

Solid front and rear axles, high ground clearance, short overhangs, robust 4x4 system (Command-Trac or optional Rock-Trac).

Durability:

Built for rugged use and off-road abuse, known for its robust construction.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain Axles:

Suspension:

Brakes:

Steering:

Electrical System:

Body And Chassis:

HVAC:

Interior Trim:

Diagnostic Troubleshooting:

Maintenance Schedules:

Wiring Diagrams:

Page Count

Estimated Pages:

~1500-2000+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed diagnostics, component testing, fuel injection, ignition system, emissions controls.

Powertrain:

Engine overhaul, clutch, flywheel, torque converter, driveline components (e.g., NV241 transfer case).

Chassis Suspension Steering:

Coil spring suspension, shock absorbers, ball joints, tie rod ends, steering gear, power steering system.

Braking System:

Front and rear disc brakes, ABS (if equipped), hydraulic system, parking brake.

Electrical Diagnostics:

Battery, charging system, starting system, lighting, instrumentation, power windows, locks, wipers, horns, fuses, relays.

Climate Control:

Air conditioning system, heater core, blower motor, controls.

Body And Frame:

Body panel removal and installation, doors, hood, tailgate, interior trim, convertible top mechanisms.

Safety Systems:

Seat belts, airbags (if applicable), and related diagnostics.

Procedures Included

Routine Maintenance:

Oil changes, fluid checks and top-offs, filter replacements, tire rotation, spark plug replacement.

Component Replacement:

Alternator, starter motor, water pump, radiator, brake pads and rotors, clutch assembly, universal joints, wheel bearings.

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and complex faults, using symptom-based guides.

Rebuilding Overhaul:

Detailed instructions for engine and transmission rebuilds.

Electrical Repairs:

Wiring harness repair, component testing, circuit diagnosis.

Alignment And Balancing:

Wheel alignment specifications and procedures.

Exhaust System:

Catalytic converter, mufflers, pipes replacement.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic strategies and wiring schematics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (OCR layer)

Print Quality

Print Capability:

Printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-Cylinder

Engine Code:

4.0L (242 ci) OHV I6 'Power Tech'

Displacement:

3952 cc

Bore X Stroke:

3.875 in x 3.575 in (98.5 mm x 90.8 mm)

Compression Ratio:

8.75:1

Performance

Horsepower Peak:

190 hp @ 4,600 rpm

Torque Peak:

235 lb-ft @ 3,200 rpm

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless Ignition System (DIS)

Cooling System

Coolant Capacity:

Approx. 13.5 quarts (12.8 liters)

🔧 Transmission

Standard

Transmission Type:

Manual

Manual Transmission Model:

AX-15 (early TJ, phased out for NSG 370)

Manual Transmission Model 2004:

NSG 370 (6-speed)

Optional

Transmission Type:

Automatic

Automatic Transmission Model:

42RLE (4-speed automatic)

Features

Transfer Case:

NV241 GII Command-Trac (standard), NV241 OR Rock-Trac (optional on Rubicon)

Transfer Case Gear Ratios:

Command-Trac: 2.72:1 low range; Rock-Trac: 4.0:1 low range

Fluid Type

Automatic Transmission Fluid:

ATF+4 (Chrysler Mopar Material Standard MS-9602)

Manual Transmission Fluid:

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

Transfer Case Fluid:

Mopar NV241 Transfer Case Lubricant (or equivalent SAE 75W-90 GL-3/GL-4)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

72.6 inches (1844 mm) (with hardtop)

Ground Clearance:

Approx. 8.5 inches (216 mm)

Weights

Curb Weight:

Approx. 3,300 - 3,500 lbs (1497 - 1588 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4,400 lbs (1996 kg)

Towing

Max Towing Capacity:

2,000 lbs (907 kg)

Max Tongue Weight:

200 lbs (91 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4 out of 5 stars (typical for its class and era, specific 2004 rating may vary slightly)

Active Features

Standard on all 4x4 models for 2004 (Front disc, Rear disc).

Passive Features

Airbags:

Driver and passenger front airbags.

Seat Belts:

3-point front seat belts, 2-point rear seat belts (lap belts).

Structural

Frame Construction:

Body-on-frame construction for durability and off-road resilience.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/CD or cassette player, optional Infinity sound system.

Navigation:

Not typically factory-equipped on base models for this year; aftermarket units common.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Connectivity

Auxiliary Input:

Rarely standard; aftermarket solutions for AUX or Bluetooth are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (4,800-12,000 km) or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendation).

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement:

Typically every 100,000 miles (160,000 km) for the 4.0L engine with platinum-tipped spark plugs.

Coolant Flush:

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

Fluid Specifications

Engine Oil Type:

SAE 10W-30 (preferred for the 4.0L engine under most conditions, consult owner's manual for variations).

Engine Oil Capacity:

6 quarts (5.7 liters) with filter change.

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Mopar Power Steering Fluid or ATF+4

Known Issues

Common Wear Items:

Ball joints, tie rod ends, control arm bushings (due to off-road use and suspension design).

Engine Issues:

Oil filter adapter housing leaks (common on 4.0L), CPS (Crankshaft Position Sensor) failure.

Transmission Issues:

Clutch wear on manual transmissions, potential for 42RLE automatic transmission issues if not maintained.

Electrical Issues:

Ground strap issues, window regulator failures, common Jeep electrical gremlins if not properly maintained.

Rust Corrosion:

Frame rust, especially in regions with road salt, and body panel rust (wheel wells, rocker panels).

📚 Vehicle History

Brand Heritage

Brand Origin:

Jeep has a long history dating back to World War II military vehicles, known for ruggedness and off-road prowess.

Model Evolution

Tj Generation Start:

The TJ generation replaced the YJ in 1996 for the 1997 model year.

Tj Key Changes:

Key differentiator from YJ was the return to coil springs (from leaf springs) for improved ride and articulation. Introduction of the 4.0L inline-6 as the primary engine.

Tj 2004 Updates:

For 2004, the TJ received minor updates, including the availability of the 6-speed NSG 370 manual transmission, replacing the older AX-15. Minor interior and exterior trim refinements.

Production

Production Period:

1997-2006

Assembly Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

The Wrangler TJ consistently receives accolades from off-road publications and enthusiasts for its capabilities, often cited as a benchmark for its segment.

Ratings

Consumer Reports:

Mixed ratings historically due to some reliability concerns but strong scores for performance and off-road capability.

Certifications

Emission Standards:

Designed to meet EPA and CARB emission standards for the 2004 model year.