🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Product Type:

Full Service Repair Manual

Chassis Code:

TJ

👋 Introduction

Vehicle Class:

Compact SUV / Off-Road Vehicle

Key Selling Points:

Off-road capability, iconic design, open-air driving experience, robust construction

Direct Competitors:

Toyota FJ Cruiser (later models), Hummer H3, Land Rover Defender (import)

Segment Differentiation:

Unmatched off-road prowess and Jeep's heritage

Platform Architecture:

Body-on-frame construction, solid front and rear axles (standard)

Body Styles:

2-door convertible (standard), 4-door Unlimited (optional)

📋 Manual Details

Geographic Coverage:

North America

Market Segment:

Aftermarket / Professional Service

Estimated Page Count:

1500+

Manual Type:

Factory-Authorized Service Manual

Content Focus:

Maintenance, Troubleshooting, Repair, Diagnostics, Wiring Diagrams

Language:

English

Format:

Digital (PDF)

Searchability:

Fully Searchable Text

Printability:

Printable Pages

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, timing systems, cylinder heads, block, pistons, crankshaft, camshafts, valve train

Engine Performance:

Fuel injection, ignition system, emission controls, cooling system, lubrication system, turbocharger (if applicable)

Transmission Manual:

Service and repair of NV3550 (AX-15 replacement) 5-speed manual transmission

Transmission Automatic:

Service and repair of 42RLE 4-speed automatic transmission

Drivetrain:

Transfer case (NV241 G/D), front and rear axles (Dana 30, Dana 35c/44 Rear), driveshafts, CV joints, U-joints, wheel hubs

Suspension:

Front and rear suspension systems, coil springs, shock absorbers, control arms, sway bars, bushings, steering knuckles

Steering:

Power steering system, steering gear, steering column, tie rods, drag links, power steering pump

Brakes:

Front and rear brake systems (disc/disc or disc/drum depending on configuration), ABS system (if equipped), parking brake, hydraulic lines, master cylinder, calipers, rotors, pads

Electrical System:

12V battery system, charging system (alternator), starting system (starter motor), lighting system, power distribution, fuses, relays, ignition switch, body control module (BCM)

Body And Frame:

Body panels, doors, hood, fenders, bumpers, interior trim, seating, convertible top systems, chassis frame inspection and repair

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, blower motor, heater core, A/C compressor, refrigerant system, climate controls

Safety Systems:

Airbag system (SRS), seat belts, anti-lock braking system (ABS) diagnostics

Powertrain Control Modules:

PCM (Powertrain Control Module) diagnostics, component location, and wiring

Scheduled Maintenance:

Oil changes, filter replacements, fluid level checks, tire rotations, belt inspections, spark plug replacement

Troubleshooting:

Diagnostic procedures for all major systems, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all covered systems

Diagnostic Trouble Codes:

OBD-II (On-Board Diagnostics II) code definitions and diagnostic trees

Wiring Diagrams:

Complete electrical schematics for all vehicle systems, including power distribution and component tracing

Torque Specifications:

Detailed torque values for all critical fasteners throughout the vehicle

Special Tools:

Identification and usage instructions for specialized tools required for certain repair procedures

Maintenance Schedule:

Recommended service intervals based on mileage and time

Depth Of Coverage:

Comprehensive rebuild procedures, advanced diagnostics, component-level repair

Diagrams And Illustrations:

Numerous exploded views, diagrams, and step-by-step illustrations to aid understanding

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Resolution:

High-resolution, suitable for professional printing

Binding:

N/A (Digital File)

Paper:

N/A (Digital File)

⚙️ Engine Specifications

Engine Code:

2.4L DOHC (Optional - Turbocharged in some markets/trims)

Engine Displacement:

2429 cc (147.7 cu in)

Engine Type:

Inline-4 (I4)

Bore X Stroke:

87.5 mm x 100.0 mm (3.44 in x 3.94 in)

Compression Ratio:

9.1:1

Horsepower:

147 hp @ 5200 rpm

Torque:

165 lb-ft @ 4000 rpm

Engine Code:

4.0L OHV (Standard)

Engine Displacement:

3960 cc (241.6 cu in)

Engine Type:

Inline-6 (I6) - "PowerTech"

Bore X Stroke:

98.4 mm x 89.0 mm (3.87 in x 3.50 in)

Compression Ratio:

8.8:1

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Electronic Fuel Injection (MPI - Multi-Point Injection)

Fuel Type:

Unleaded Gasoline

Engine Management:

Chrysler PPEC (Powertrain Performance Engine Controller)

🔧 Transmission

Transmission Type:

NV3550 5-Speed Manual

Gear Ratios 1:

4.01:1 (1st), 2.32:1 (2nd), 1.40:1 (3rd), 1.00:1 (4th), 0.78:1 (5th), 3.73:1 (Reverse)

Transmission Type:

42RLE 4-Speed Automatic

Gear Ratios Auto:

2.80:1 (1st), 1.53:1 (2nd), 1.00:1 (3rd), 0.71:1 (4th), 2.17:1 (Reverse)

Transfer Case:

NV241 G/D Command-Trac (2-speed, part-time 4WD with 4-Hi, 4-Lo, 2-Hi, Neutral modes)

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant (or equivalent API GL-4, SAE 75W-90)

Automatic Transmission Fluid:

ATF+4 (Mopar Automatic Transmission Fluid)

Transfer Case Fluid:

Mopar Transfer Case Lubricant (or equivalent NV241 specification)

📐 Dimensions

Wheelbase:

93.4 in (2372 mm)

Length:

151.4 in (3845 mm)

Width:

66.5 in (1689 mm)

Height:

70.9 in (1801 mm)

Wheelbase:

103.4 in (2626 mm)

Length:

161.4 in (4100 mm)

Width:

66.5 in (1689 mm)

Height:

70.9 in (1801 mm)

Curb Weight 2Door:

3633 - 3845 lbs (1648 - 1744 kg) (Varies by engine/transmission)

Curb Weight 4Door Unlimited:

3897 - 4117 lbs (1768 - 1867 kg) (Varies by engine/transmission)

Gross Vehicle Weight Rating Gvwr:

Approx. 4900-5200 lbs (2223-2359 kg)

Ground Clearance:

Approx. 8.7 inches (221 mm) (stock)

Approach Angle:

41.7 degrees (stock)

Departure Angle:

37.4 degrees (stock)

Breakover Angle:

25.1 degrees (stock)

🛡️ Safety Features

NHTSA Frontal Crash Test:

Driver: 4/5 Stars, Passenger: 4/5 Stars (2004 Model Year)

ABS:

Optional Anti-lock Braking System (ABS) - typically on front wheels and rear wheels

Traction Control:

Not typically standard; some later models or specific packages might have introduced basic traction aids.

Airbags:

Driver and front passenger airbags

Seat Belts:

Three-point inertia-reel seat belts with front pretensioners

Rollover Protection:

Integral sport bar (roll cage) with side-impact protection

💡 Technology Features

Audio System:

AM/FM stereo with CD player, optional Infinity premium audio system.

Display:

Basic LCD display for radio information, climate controls.

Cruise Control:

Standard on most trims.

Navigation:

Not available from the factory for this model year.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Engine Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first.

Oil Filter Replacement:

With every oil change.

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 100,000 miles (160,000 km) with Champion Copper Plus or equivalent (check specific plug type).

Coolant Flush And Replacement:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Transmission Fluid Change Manual:

Every 60,000-100,000 miles (96,000-160,000 km).

Transmission Fluid Change Automatic:

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

Differential Fluid Change:

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

Transfer Case Fluid Change:

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

Engine Oil Type:

API Certified SAE 10W-30 (for 4.0L I6), SAE 5W-30 (for 2.4L I4) - consult owner's manual for exact specification.

Engine Oil Capacity:

4.0L I6: 6 US quarts (5.7 L), 2.4L I4: 5 US quarts (4.7 L) (with filter change)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Orange color, 50/50 mix with distilled water.

Power Steering Fluid:

Mopar Power Steering Fluid (or equivalent MS-10838 specification)

Brake Fluid:

DOT 3 Brake Fluid

Common Problem 40L:

Cracked cylinder heads (especially earlier 4.0L models), oil filter adapter leaks, rear main seal leaks, death wobble (alignment/steering component wear), exhaust manifold cracks.

Common Problem Transmission:

NV3550: Bearing noise, clutch wear. 42RLE: Torque converter issues, solenoid pack failure.

Common Problem Electrical:

Window regulator failures, HVAC blower motor resistor failure, intermittent electrical gremlins due to corrosion.

Common Problem Chassis:

Frame rust (especially in salt-belt regions), control arm bushings wear, ball joint wear.

📚 Vehicle History

Brand Origin:

Jeep's lineage traces back to World War II military vehicles, establishing a legacy of off-road capability.

Tj Generation Introduction:

The TJ Wrangler was introduced for the 1997 model year, replacing the YJ generation. It marked a significant return to coil springs and round headlights.

Tj Generation Updates 2004:

For 2004, the TJ received minor updates. The 4.0L I6 engine remained the dominant powertrain. The 'Rubicon' trim, introduced in 2003, continued to be the pinnacle of off-road factory equipment. The 'Unlimited' (LJ) model was introduced for 2004.5, offering a longer wheelbase.

Production Plant:

Toledo, Ohio, USA

Tj Production Years:

1997-2006

🏆 Awards & Recognition

Jeep Wrangler Reputation:

Consistently praised for its off-road capability and durability. Often cited in 'best off-road vehicles' lists.

Consumer Reports Reliability:

Varied, with the 4.0L engine generally considered more reliable than the 2.4L. Specific model year ratings should be checked.