Jeep Wrangler TJ 2004 Workshop Service Repair Manual Ebook

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Generation: TJ Chassis Code: TJ 👋 Introduction Market Position Market Position: The Jeep Wrangler TJ 2004 Workshop Service Repair Manual...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Generation:

Chassis Code:

👋 Introduction

Market Position

Market Position:

The Jeep Wrangler TJ 2004 Workshop Service Repair Manual Ebook serves as an indispensable resource for owners and technicians alike, positioning itself as the definitive guide for maintaining and repairing this iconic off-road vehicle. It provides dealership-level expertise accessible to a broad user base.

Competitive Analysis

Competitive Analysis:

Compared to generic repair guides or owner's manuals, this factory-produced workshop manual offers significantly greater depth and accuracy. It's the same documentation relied upon by authorized Jeep service centers, ensuring users have access to the most precise diagnostic and repair procedures.

Key Features

Key Features List:

• Instant Download

• No Shipping Costs

• No waiting for physical media

• Comprehensive coverage of all vehicle systems

• Dealership-level repair information

• Detailed wiring diagrams

• Troubleshooting guides

• Torque specifications

• Maintenance schedules

📋 Manual Details

Coverage Areas

Coverage Areas List:

• General Information

• Lubrication and Maintenance

• Engine

• Cooling System

• Fuel System

• Exhaust System

• Clutch

• Transmission and Transfer Case

• Differential and Driveline

• Suspension

• Steering

• Brakes

• Frame and Bumpers

• Body

• Heating and Air Conditioning

• Emission Control Systems

• Battery

• Starting Systems

• Charging System

• Ignition System

• Instrument Panel Systems

• Audio Systems

• Horn Systems

• Speed Control System

• Turn Signal and Hazard Warning Systems

• Wiper and Washer Systems

• Lamps

• Passive Restraint Systems

• Electrically Heated System

• Power Distribution System

• Vehicle Theft/Security Systems

• Chime/Buzzer Warning Systems

• Wiring Diagrams

• Tires and Wheels

• Seats System

• Locks

Manual Type

Manual Type:

Factory Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

PDF/ZIP Ebook

Page Count

Estimated Page Count:

Varies by specific edition, but typically ranges from 1500-2500 pages for a complete factory workshop manual.

📖 Manual Coverage

Systems Covered

Systems Covered Description:

This comprehensive manual covers all major mechanical, electrical, and body systems of the Jeep Wrangler TJ 2004. It provides detailed information on engine diagnostics and repair, drivetrain components including transmission and transfer case, suspension and steering systems, brake system servicing, fuel and exhaust systems, and all electrical systems from the battery to lighting and accessories. It also details bodywork, climate control, and emission control systems.

Specific System Cover Chassis:

Includes detailed information on frame construction, suspension components (front and rear coil springs, shock absorbers, control arms, sway bars, bushings), steering linkage, and wheel hub assemblies.

Procedures Included

Procedures Included List:

• Routine Maintenance (oil changes, fluid checks, filter replacements)

• Engine Overhaul and Rebuilds

• Transmission and Transfer Case Service and Repair

• Differential and Axle Service

• Brake System Inspection, Repair, and Bleeding

• Suspension Component Replacement (shocks, springs, bushings)

• Steering System Diagnosis and Repair

• Fuel System Diagnosis and Component Replacement

• Cooling System Maintenance and Repair

• Electrical System Troubleshooting and Component Repair (starting, charging, ignition)

• Lighting System Service

• Instrument Cluster and Gauge Repair

• Audio System Installation and Repair

• Wiper and Washer System Service

• Climate Control System Service (HVAC)

• Emission Control System Diagnosis

• Body Panel Repair and Adjustment

• Seat and Lock System Repair

• Wiring Diagram Interpretation and Fault Finding

• Wheel and Tire Service and Specifications

Specific Procedure Engine Diagnosis:

Detailed diagnostic trees for misfires, no-start conditions, overheating, oil pressure issues, and emissions-related faults. Includes spark plug firing order, ignition timing specifications, and compression test procedures.

Specific Procedure Brakes:

Complete procedures for brake pad replacement, rotor servicing, caliper overhaul, brake line inspection and replacement, and ABS system bleeding.

Specific Procedure Steering:

Diagnosis and repair of steering gear, power steering pump and hoses, steering linkage, and steering column components. Includes alignment specifications.

Specific Procedure Electrical:

Extensive wiring diagrams for all circuits, component location charts, diagnostic procedures for starting, charging, lighting, and all interior/exterior electrical accessories. Includes fuse and relay specifications.

Specific Procedure Transmission Overhaul:

Step-by-step instructions for the removal, disassembly, inspection, repair, and reassembly of both the manual (NV3550/AX-15) and automatic (42RLE) transmissions, including torque specifications for internal components.

Technical Depth

Technical Depth Level:

Factory-Level (Dealership Standard)

Technical Depth Description:

The manual offers a high level of technical detail, suitable for professional technicians and experienced DIY mechanics. It includes diagnostic procedures, component specifications, torque values, repair procedures, and troubleshooting guides for complex systems. Wiring diagrams are provided in detail, allowing for in-depth electrical system diagnosis.

Diagnostic Tools Required:

Standard automotive hand tools, multimeter, scan tool (for OBD-II diagnostics), vacuum gauge, pressure gauges (fuel, oil, coolant), torque wrench.

Troubleshooting Methodology:

The manual employs a systematic troubleshooting approach, starting with basic checks and progressing to more complex diagnostics. It utilizes symptom-based troubleshooting charts and provides guidance on interpreting diagnostic trouble codes (DTCs).

📊 Manual Specifications

File Format

File Type:

Digital Ebook (PDF/ZIP)

Print Quality

Print Quality:

High Resolution, Searchable Text, Printable

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Compatibility

Operating Systems:

Windows (95/98/ME/XP/Vista/7), Linux, MAC

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-Cylinder, Overhead Valve (OHV)

Engine Displacement:

4.0 Liters (242 cubic inches)

Engine Code:

ERH (for 4.0L)

Performance

Horsepower:

Approx. 190 hp @ 4600 rpm

Torque:

Approx. 235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Components

Engine Block Material:

Cast Iron

Cylinder Head Material:

Cast Iron

Engine Options

Available Engines:

4.0L Inline-6 (ERH)

🔧 Transmission

Standard Transmission

Transmission Type:

6-Speed Manual Transmission

Optional Transmission

Transmission Type:

4-Speed Automatic Transmission

Transfer Case

Transfer Case Model:

NV241 GII (Command-Trac)

Transfer Case Features:

Part-time, 2-speed with 4WD Hi, 4WD Lo, and Neutral positions

Transmission Features

Transmission Features List:

• Durable design suitable for off-road use

• Provision for PTO (Power Take-Off) on some manual transmissions

• Transfer case low-range gearing for extreme off-road conditions

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

158.8 inches (4033 mm)

Width:

66.5 inches (1689 mm)

Height:

72.0 inches (1829 mm)

Weights

Curb Weight:

Approx. 3,400 - 3,700 lbs (1542 - 1678 kg)

Gross Vehicle Weight Rating:

Approx. 4,750 - 5,000 lbs (2155 - 2268 kg)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 14.3 cubic feet

Cargo Volume With Rear Seat Folded:

Approx. 43.4 cubic feet

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-Star

Active Features

Active Safety Features List:

• Four-Wheel Anti-lock Braking System (ABS)

Passive Features

Passive Safety Features List:

• High-strength steel frame and chassis

• Seat belts with pretensioners

• Child seat anchor systems (LATCH)

💡 Technology Features

Infotainment

Infotainment System Description:

Base audio systems typically featured AM/FM radio with a CD player or cassette player. Optional upgrades included premium sound systems with more speakers. Bluetooth or advanced navigation were not standard features in this era.

Driver Assistance

Driver Assistance Features List:

• Cruise Control (Speed Control System)

Connectivity

Connectivity Features Description:

Limited connectivity. Primarily focused on basic audio playback. No integrated smartphone connectivity or Wi-Fi hotspot capabilities.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 6,000 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Tire Rotation Interval:

Every 6,000 to 8,000 miles

Transmission Fluid Change Interval Auto:

Approximately every 50,000 miles or as per severe service schedule.

Transmission Fluid Change Interval Manual:

Check and top-up as needed, replace if contamination occurs.

Fluid Specifications

Engine Oil Type:

SAE 10W-30 (API Service SG, SH, SJ or higher)

Engine Oil Capacity:

5.0 quarts (4.7 Liters) with filter

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant or equivalent (50/50 mix with distilled water)

Transmission Fluid Type Auto:

ATF+4 (Mopar)

Transmission Fluid Type Manual:

API GL-3 or GL-4, SAE 75W-90 (for NV3550) / SAE 75W-85 (for AX-15)

Transfer Case Fluid Type:

Mopar NV241 Transfer Case Lubricant or equivalent (SAE 75W-85)

Differential Fluid Type Front Rear:

API GL-5, SAE 75W-90 (for non-LSD) / SAE 80W-90 (for LSD)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 (Mopar) or equivalent

Known Issues

Common Issues List:

• Wrangler Lean (sagging suspension on one side)

• Death Wobble (severe steering shimmy at speed)

• Cracked exhaust manifolds (4.0L engine)

• Radiator leaks

• Water pump failures

• Clutch pedal issues (manual transmission)

• Actuator failures for HVAC blend doors

• Oil filter housing leaks

Specific Known Issue Detail Death Wobble:

Often caused by worn steering components (tie rod ends, drag link, track bar bushings, ball joints) or improper tire balance and inflation. Requires thorough inspection and replacement of worn parts.

Specific Known Issue Detail Exhaust Manifold:

The 4.0L engine's exhaust manifolds are prone to cracking due to heat cycling. Symptoms include ticking noise on startup or acceleration, and potential loss of exhaust back pressure affecting performance. Replacement with updated designs or high-performance headers is common.

📚 Vehicle History

Brand Heritage

Brand Heritage Summary:

Jeep has a storied history dating back to World War II, evolving into a symbol of ruggedness, off-road capability, and adventure. The Wrangler nameplate directly inherits this legacy, representing the modern iteration of the classic Jeep concept.

Model Evolution

Model Evolution Summary:

The TJ generation of the Wrangler (1997-2006) marked a significant modernization for the model, notably introducing coil springs for all four wheels, replacing the previous leaf spring setup. This improved on-road comfort and handling while retaining its renowned off-road prowess. The 2004 model year saw minor updates but remained fundamentally the same capable platform.

Key Changes For 2004 Model:

Minor updates for 2004, often included revised interior trim options and potentially minor feature additions depending on the trim level. The core mechanicals and chassis remained largely the same as previous TJ models.

Production

Production Years For Tj Model:

1997-2006

Manufacturing Plant:

Toledo, Ohio, USA