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Jeep Wrangler 2006 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2006 Codes Model Code: TJ 👋 Introduction Market Position Segment: Compact Sport Utility Vehicle (SUV), Off-Road Focused Segment Description: The 2006...
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🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
2006
Codes
Model Code:
TJ
👋 Introduction
Market Position
Segment:
Compact Sport Utility Vehicle (SUV), Off-Road Focused
Segment Description:
The 2006 Jeep Wrangler (TJ) solidified its reputation as the quintessential off-road vehicle, emphasizing capability and ruggedness over comfort and fuel economy.
Competitive Analysis
Key Competitors:
Toyota FJ Cruiser (later models), Hummer H3, Land Rover Defender (in certain markets)
Unique Selling Proposition:
True body-on-frame construction, solid front and rear axles, exceptional off-road articulation and capability, iconic open-air experience with removable doors and top.
Key Features
Off Road Capability:
Solid front and rear axles, coil spring suspension, available locking differentials (Rubicon model), high ground clearance.
Versatility:
Removable doors, removable windshield, removable soft top or hardtop options for an open-air driving experience.
Durability:
Robust body-on-frame construction designed to withstand the rigors of off-road use.
📋 Manual Details
Coverage Areas
Primary Coverage:
All systems and components of the 2006 Jeep Wrangler
Engine Coverage:
4.0L (122ci) Inline-6 (PowerTech) engine
Transmission Coverage:
NV3550 5-Speed Manual Transmission, 42RLE 4-Speed Automatic Transmission
Drivetrain Coverage:
NV241OR 'Rubicon Express' Transfer Case, Dana 30 Front Axle, Dana 44 Rear Axle
Suspension Coverage:
Front and Rear Coil Spring Suspension, Shock Absorbers, Steering System
Brake Coverage:
Front Disc Brakes, Rear Disc Brakes, ABS System
Electrical Coverage:
Wiring Diagrams, Fuses, Relays, Lighting, Power Accessories, Engine Control Module (ECM), Body Control Module (BCM)
Body Coverage:
Body Panels, Doors, Hood, Soft Top/Hard Top Removal and Installation, Interior Trim
HVAC Coverage:
Heating, Ventilation, and Air Conditioning (HVAC) System
Diagnostic Coverage:
Diagnostic Trouble Codes (DTCs), OBD-II Procedures, Troubleshooting Flowcharts
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual
Synonymous Terms:
Repair Manual, Shop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Fuel system, ignition system, cooling system, exhaust system, lubrication system, engine mechanical (disassembly, assembly, overhaul)
Drivetrain:
Clutch, transmission, transfer case, drive shafts, axles, differentials (service, repair, overhaul)
Chassis:
Frame, suspension components (control arms, springs, shocks), steering system (rack and pinion, power steering), wheels and tires
Braking:
Brake system components (master cylinder, calipers, rotors, pads), parking brake, ABS system
Electrical System:
Battery, charging system, starting system, ignition system, lighting, instrument cluster, power windows, power locks, wipers, horn, wiring diagrams for all circuits
Body And Interior:
Body panels, bumpers, doors, latches, hinges, convertible top mechanism, interior trim, seats, airbags
HVAC:
Air conditioning system, heater core, blower motor, controls, refrigerant handling
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, tire rotations, brake inspections, spark plug replacement
Component Removal Installation:
Step-by-step instructions for removing and installing all major components (engine, transmission, axles, suspension, brakes, etc.)
Troubleshooting:
Diagnostic flowcharts for common and uncommon problems, symptom-based troubleshooting guides
Overhaul Rebuild:
Detailed procedures for complete engine, transmission, and axle overhauls, including specifications and clearances
Wiring Diagrams:
Comprehensive, color-coded wiring diagrams for all electrical systems, including component locations and connector pinouts
Specifications Tolerances:
Torque specifications, engine clearances, bearing preloads, measurement data for all critical components
Technical Depth
Depth:
Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (text-searchable PDF)
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Name:
PowerTech (AMC 242) Inline-6
Displacement:
4.0 Liters (242 cubic inches)
Configuration:
Inline 6-Cylinder
Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Compression Ratio:
8.8:1
Performance
Horsepower:
190 hp @ 4600 rpm
Torque:
235 lb-ft @ 3200 rpm
Fuel System
Induction:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane recommended)
Lubrication
Oil Type:
SAE 10W-30 (API Service SG or higher)
Oil Capacity:
5.8 Quarts (5.5 Liters) with filter
Cooling System
Coolant Type:
Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, Blue (Chrysler MS-9769)
Coolant Capacity:
10.5 Quarts (9.9 Liters)
🔧 Transmission
Standard
Transmission Type:
NV3550 5-Speed Manual
Optional
Transmission Type:
42RLE 4-Speed Automatic
Features
Manual Gear Ratios:
1st: 3.75, 2nd: 2.19, 3rd: 1.40, 4th: 1.00, 5th: 0.79
Automatic Gear Ratios:
1st: 2.80, 2nd: 1.57, 3rd: 1.00, 4th: 0.71
Fluid Manual
Manual Transmission Fluid Type:
Mopar Manual Transmission Lubricant (MS-9070) or equivalent API GL-3 SAE 75W-90
Fluid Automatic
Automatic Transmission Fluid Type:
ATF+4 (Chrysler Material Standard MS-9602)
Transfer Case
Transfer Case Model:
NV241OR (Command-Trac) or NV241OR-HD (Rubicon Express)
Transfer Case Fluid
Transfer Case Fluid Type:
Mopar Automatic Transmission Fluid (ATF+4) or equivalent
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
158.5 inches (4026 mm)
Width Body:
66.5 inches (1689 mm)
Height:
70.9 inches (1801 mm) (with hardtop)
Ground Clearance:
8.8 inches (224 mm) (stock)
Approach Angle:
41 degrees
Departure Angle:
35 degrees
Breakover Angle:
25 degrees
Weights
Curb Weight:
Approx. 3,400 - 3,700 lbs (1542 - 1678 kg)
Gross Vehicle Weight Rating:
Approx. 4,550 lbs (2064 kg)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 13.4 cubic feet (379 Liters)
Cargo Volume Max:
Approx. 46.5 cubic feet (1317 Liters) (with rear seat folded)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
3 Stars (may vary by configuration)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Not standard, available on some models/trims.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point seat belts with pretensioners for front occupants.
Roll Cage:
Integral sport bar (roll bar) for occupant protection.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with cassette and/or CD player. Optional premium sound systems with subwoofer.
Display:
No integrated infotainment screen. Basic analog gauges and indicator lights.
Driver Assistance
Cruise Control:
Available on most models.
Navigation:
Not available from factory.
Connectivity
Bluetooth:
Not available from factory. Aftermarket solutions common.
Usb Ports:
Not available from factory.
🔧 Maintenance
Service Intervals
Engine Oil Filter Change:
Every 3,000-6,000 miles (5,000-10,000 km) or every 6 months, depending on driving conditions (severe vs. normal).
Engine Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) for standard plugs, potentially longer for platinum/iridium.
Transmission Fluid Change Manual:
Every 30,000-50,000 miles (48,000-80,000 km).
Transmission Fluid Change Automatic:
Every 30,000-50,000 miles (48,000-80,000 km).
Transfer Case Fluid Change:
Every 30,000-50,000 miles (48,000-80,000 km).
Coolant Flush Replacement:
Every 30,000 miles (48,000 km) or 2 years for conventional coolant, longer for OAT.
Fluid Specifications
Power Steering Fluid:
Chrysler Power Steering Fluid (MS-5901) or equivalent (ATF+4 may be acceptable in some applications, verify with manual).
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Common Issues:
Rear main seal leaks, oil filter adapter O-ring leaks, exhaust manifold cracks, clutch wear (manual transmission), transmission synchronizer issues, heater core leaks, rear axle seal leaks.
Common Issues
Electrical Issues:
Intermittent issues with turn signals, brake lights, or power accessories; aging wiring harnesses.
Suspension Wear:
Worn ball joints, tie rod ends, and bushings due to off-road use and age.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long and storied history dating back to World War II, synonymous with off-road capability and rugged utility.
Model Evolution
Tj Generation:
The TJ generation (1997-2006) marked a significant return to Jeep's roots with the reintroduction of coil springs and solid axles, replacing the previous leaf-spring setup of the YJ.
Notable Trims:
Sport, Sahara, X, Rubicon (offering enhanced off-road features like locking differentials and Dana 44 axles).
Production
Production Period:
1997-2006
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
Consistently recognized by off-road publications and enthusiasts for its class-leading off-road capability and iconic design.
Ratings
Consumer Satisfaction:
Mixed; praised for capability, criticized for on-road manners and interior refinement compared to modern SUVs.
Certifications
Emissions Standards:
Meets relevant US EPA emissions standards for the 2006 model year.