Positioning:
The Jeep Wrangler TJ is an iconic off-road vehicle, known for its ruggedness and versatility. This manual caters to owners and technicians who value maintaining and repairing this capable machine.
Competition:
Competes with other off-road focused vehicles of its era, but the TJ's coil-spring suspension and iconic design set it apart. Manuals for such vehicles are critical for preserving their unique capabilities.
Manual Features:
OEM specifications, step-by-step repair procedures, exploded diagrams, comprehensive charts and illustrations, detailed electrical schematics, and diagnostic flowcharts.
Primary Coverage:
Repair and maintenance for 2005 Jeep Wrangler TJ
Secondary Coverage:
Tune-ups, lubrication, major engine and transmission rebuilds
Estimated Page Count:
1500-2000+ (Typical for comprehensive FSMs)
Type:
Factory Service Manual / Workshop Manual
Format:
Printed (typically)
Powertrain:
Engine (4.0L I6, 2.4L I4), Fuel System, Cooling System, Exhaust System, Transmission (NV3550 Manual, 42RLE Automatic), Transfer Case (NV241OR).
Chassis:
Suspension (Solid Front/Rear Axles, Coil Springs, Shocks), Steering System, Brakes (Front Disc, Rear Disc/Drum options), Drivetrain (Axles, Driveshafts, U-joints).
Electrical:
Battery, Starting System, Charging System, Ignition System, Lighting, Instrumentation, Body Control Modules, Powertrain Control Module (PCM), HVAC Controls, Power Accessories.
Body:
Frame, Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Restraints (Airbags), Glass, Weatherstripping.
Routine Maintenance:
Oil changes, fluid checks and replacements, filter changes, lubrication, tire rotations.
Major Repairs:
Engine rebuilds, transmission overhauls, clutch replacement, transfer case rebuild, differential servicing, brake system overhauls.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, electrical schematic interpretation, DTC (Diagnostic Trouble Code) explanations.
Specifications And Data:
Torque specifications, fluid types and capacities, electrical data, connector pinouts, compression test ranges, alignment specifications.
Depth:
Comprehensive, from basic fluid checks to complete powertrain and chassis component rebuilds. Includes detailed diagnostic procedures and electrical troubleshooting.
Digital Format:
Typically provided as a PDF for digital versions, though the original is printed.
Print Quality:
High-resolution scans or original print quality, ensuring clarity of diagrams and text.
Binding Type:
Perfect bound or coil-bound for printed versions, facilitating ease of use on a workbench.
Paper Type:
Durable, high-quality paper suitable for workshop environments.
Engine Model:
4.0L Inline-6 "High Output" (OHV)
Displacement:
3952 cc (241 cubic inches)
Bore X Stroke:
3.875 in x 3.563 in (99.0 mm x 90.5 mm)
Horsepower Rating:
190 hp @ 4600 rpm (approx.)
Torque Rating:
235 lb-ft @ 3200 rpm (approx.)
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Pressure:
31-39 PSI (typical for MPI systems)
Spark Plugs:
Champion Copper Plus (e.g., RC12MCC4) or equivalent
Oil Type:
SAE 10W-30 API SJ or SL (refer to manual for specific Chrysler specification)
Oil Capacity:
5 quarts (4.7 liters) with filter
NHTSA Front Crash:
4 Stars (for 2005 model year)
IIHS Frontal Offset:
Good (for 2005 model year)
ABS:
Standard on front wheels, optional on rear wheels (typically part of a package).
Airbags:
Driver and Passenger front airbags.
Seatbelts:
Three-point front seatbelts, lap belts in rear.
Oil Change Interval:
Every 3,000 - 5,000 miles or 6 months (refer to manual for specific recommendation based on driving conditions).
Transmission Fluid Change:
Manual: Check for leaks, typically no set interval unless service is performed. Automatic: Every 30,000 - 50,000 miles.
Transfer Case Fluid Change:
Every 30,000 - 50,000 miles.
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years.
Power Steering Fluid:
Chrysler MS-5901 or equivalent (typically ATF+4 compatible)
Common Wear Items:
U-joints, ball joints, clutch wear (manual transmission), water pump, radiator, exhaust manifold cracks (4.0L), sway bar links, tie rod ends.
Common Electrical Issues:
Crankshaft position sensor failure, instrument cluster intermittent failures, PCM connector corrosion.
Jeep Legacy:
Jeep has a storied history dating back to WWII, synonymous with off-road capability and adventure.
Tj Generation:
The TJ generation (1997-2006) marked a significant return to Jeep's roots with the introduction of coil springs, replacing the previous leaf-spring setup, offering a more refined ride and improved articulation.
2005 Updates:
The 2005 model year saw minor updates, often including new option packages and color choices, while retaining the core TJ platform.
Manufacturing Location:
Toledo, Ohio, USA
