🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Model Years Covered:

2005, 2006, 2007

Chassis Code:

TJ

👋 Introduction

Vehicle Segment:

Compact Sport Utility Vehicle (SUV) with exceptional off-road capability.

Jeep Heritage:

Continues the Jeep legacy of ruggedness, open-air driving, and go-anywhere performance.

Key Competitors:

Toyota Tacoma (off-road variants), Ford Bronco (older generations), Nissan Xterra.

Iconic Design:

Round headlights, seven-slot grille, exposed hinges, and removable doors/top for the ultimate open-air experience.

Off Road Prowess:

Solid front and rear axles, ample ground clearance, available locking differentials, and robust four-wheel-drive systems.

Customization Platform:

Highly popular for aftermarket modifications and upgrades, making it a favorite among off-road enthusiasts.

📋 Manual Details

Manual Type:

Factory Service Workshop Manual

Language:

English

Format:

Digital Download (likely PDF)

Shipping Cost:

No Shipping Cost

Download Availability:

Free Download

Estimated Page Count:

Typically 1000+ pages for a complete factory service manual of this era.

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for the 4.0L inline-6 engine, including cylinder head, block, pistons, crankshaft, camshaft, and timing components. Includes torque specifications, clearances, and assembly sequences.

Engine Fuel System:

Diagnosis and repair of fuel pump, injectors, fuel pressure regulator, fuel lines, and evaporative emissions system (EVAP). Includes fuel system pressure testing and component specifications.

Engine Ignition System:

Information on spark plugs, ignition coils, crankshaft position sensor, camshaft position sensor, and ignition timing adjustments (where applicable).

Engine Cooling System:

Procedures for radiator, water pump, thermostat, hoses, and fan clutch replacement. Includes coolant capacity and fill procedures.

Engine Lubrication System:

Oil pump, oil pan, oil filter housing, and oil pressure troubleshooting. Includes oil capacity and recommended oil types.

Transmission Manual:

Service and repair for the NV3550 5-speed manual transmission, including clutch operation, gear train, synchronizers, and shift mechanism. Includes fluid type and capacity.

Transmission Automatic:

Service and repair for the 42RLE 4-speed automatic transmission, including valve body, torque converter, planetary gear sets, and electronic controls. Includes fluid type and capacity.

Drivetrain Transfer Case:

Service and repair for the NP231 Command-Trac NV241OR Off-Road transfer case (depending on trim), including chain wear, gear inspection, and seal replacement. Includes fluid type and capacity.

Drivetrain Axles Front:

Diagnosis and repair of Dana 30 front axle, including universal joints, axle shafts, differential gear setup, and hub assembly. Includes lubricant specifications.

Drivetrain Axles Rear:

Diagnosis and repair of Dana 35c or Dana 44 rear axle (depending on trim), including universal joints, axle shafts, differential gear setup, and axle housing. Includes lubricant specifications.

Brakes Front:

Service and repair for front disc brakes, including caliper, rotor, pad replacement, and brake line bleeding. Includes fluid type (DOT 3) and specifications.

Brakes Rear:

Service and repair for rear disc brakes (most models) or drum brakes (some early models), including caliper/wheel cylinder, rotor/drum, and pad/shoe replacement. Includes fluid type and specifications.

Steering System:

Diagnosis and repair of steering gearbox, power steering pump, steering linkage, and tie rod ends. Includes power steering fluid type and capacity.

Suspension Front:

Service for leaf springs, shock absorbers, sway bar, and control arms (if applicable). Includes alignment specifications.

Suspension Rear:

Service for leaf springs, shock absorbers, and track bar (if applicable). Includes alignment specifications.

Electrical System Charging:

Diagnosis and repair of alternator, voltage regulator, and battery. Includes testing procedures and specifications.

Electrical System Starting:

Diagnosis and repair of starter motor, starter solenoid, and ignition switch. Includes testing procedures.

Electrical System Lighting:

Troubleshooting and replacement of headlights, taillights, turn signals, and interior lighting. Includes bulb types and wiring diagrams.

Electrical System Accessories:

Service for power windows, power door locks, wipers, horn, and radio systems. Includes fuse box layouts and wiring diagrams.

Body Exterior:

Body panel alignment, door and tailgate adjustments, convertible top service (where applicable), and trim piece replacement. Includes paint code information.

Body Interior:

Dashboard removal and installation, seat adjustment and removal, and interior trim panel service. Includes airbag system precautions.

Heating Ventilation Air Conditioning HVAC:

Diagnosis and repair of blower motor, evaporator, condenser, heater core, and refrigerant system. Includes refrigerant type and charging procedures.

Powertrain Control Module PCM:

Information on PCM diagnostics, reprogramming, and common fault codes (DTCs). Includes sensor and actuator identification.

Safety Systems Airbags:

Information on airbag system operation, diagnostic codes, and safety precautions during servicing. Includes module replacement procedures.

Preventive Maintenance:

Detailed schedules for oil changes, filter replacements, fluid checks and changes, tire rotations, and inspections.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting and flowcharts.

Component Replacement:

Step-by-step instructions for replacing virtually every component on the vehicle, from minor sensors to major engine and transmission assemblies.

Rebuild Procedures:

Comprehensive instructions for rebuilding major components such as the engine, transmission, and axles.

Adjustment Procedures:

Procedures for adjusting brakes, clutch, parking brake, and suspension components.

Diagnostics And Testing:

Guidance on using diagnostic tools, interpreting sensor data, and performing specific component tests.

Torque Specifications:

Extensive list of torque values for all critical fasteners throughout the vehicle.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems, including component locations and wire colors.

Depth Of Coverage:

Comprehensive, covering everything from basic fluid changes and filter replacements to complete engine and transmission overhauls, advanced electrical diagnostics, and bodywork repairs.

Target Audience:

Professional dealer technicians, experienced DIY mechanics, and dedicated Jeep TJ enthusiasts.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick navigation to specific topics.

Printability:

Designed to be printable for users who prefer a physical copy.

Image Resolution:

High resolution for clear diagrams, illustrations, and photographs.

Digital Format Advantage:

Instant access and portability across multiple devices.

Digital Content Type:

Includes detailed text, exploded views, wiring diagrams, charts, and diagnostic flowcharts.

⚙️ Engine Specifications

Engine Type:

4.0L (242 cubic inch) Inline 6-Cylinder (I6)

Engine Code:

ERH (for 2005-2006), likely same or similar for 2007.

Horsepower:

Approximately 190 hp @ 4600 rpm (figures may vary slightly by year)

Torque:

Approximately 235 lb-ft @ 3200 rpm (figures may vary slightly by year)

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Bore X Stroke:

3.875 in x 3.375 in (98.4 mm x 85.7 mm)

Compression Ratio:

8.8:1

Valvetrain:

Overhead Valve (OHV) with Pushrods and Rocker Arms

🔧 Transmission

Transmission Type Standard:

NV3550 5-Speed Manual Transmission

Transmission Type Optional:

42RLE 4-Speed Automatic Transmission

Clutch Type Manual:

Hydraulic Actuated Dry Single Plate

Transmission Fluid Manual:

Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4) - Capacity approx. 2.3 quarts

Transmission Fluid Automatic:

ATF+4 (Chrysler Mopar)

Automatic Transmission Control:

Electronic

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

157.0 inches (3988 mm)

Width Body:

66.7 inches (1694 mm)

Height:

70.1 inches (1780 mm)

Curb Weight Approx:

3500 - 3700 lbs (1588 - 1678 kg), depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 4750 lbs (2154 kg)

🛡️ Safety Features

NHTSA Front Impact:

Good (for 2005-2006 models, based on available data for similar era Jeeps, specific TJ ratings may vary)

NHTSA Side Impact:

Not Rated or Acceptable (specific data for TJ side impact is limited, older SUVs often had lower ratings).

ABS:

Standard on all four wheels (4-wheel Anti-lock Braking System)

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point seat belts with pretensioners

💡 Technology Features

Audio System:

AM/FM stereo with CD player (optional satellite radio), 4-6 speaker system.

Climate Control:

Manual or optional air conditioning system.

Cruise Control:

Available

Power Features:

Optional power windows and door locks (introduced on some trims in later TJ years, but not standard across all models).

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics).

Engine Air Filter Replacement:

Every 15,000-30,000 miles, or as needed based on inspection.

Spark Plug Replacement:

Approximately every 30,000-100,000 miles depending on spark plug type (standard copper vs. platinum/iridium).

Engine Oil Specification:

SAE 5W-30 Synthetic or Conventional Engine Oil. Capacity approx. 6 quarts (5.7 L) with filter.

Coolant Specification:

Chrysler HOAT (Hybrid Organic Acid Technology) Blue Coolant. 50/50 mix with distilled water. Capacity approx. 11.3 quarts (10.7 L).

Brake Fluid Specification:

DOT 3.

Common Issues Engine:

Oil filter adapter O-ring leaks, cracked exhaust manifolds, occasional cylinder head issues (though the 4.0L is generally robust).

Common Issues Suspension:

Worn control arm bushings, worn track bar bushings, leaking shock absorbers, potential frame rust in severe climates.

Common Issues Electrical:

Faulty clockspring in the steering wheel, intermittent wiper issues, minor electrical gremlins related to age.

Common Issues Transmission:

Manual clutch wear, automatic transmission solenoid issues.

Common Issues Drivetrain:

U-joint wear, differential seal leaks, axle shaft issues (especially on Dana 35c if used heavily off-road).

📚 Vehicle History

Jeep Legacy:

Jeep has a storied history dating back to World War II, synonymous with off-road capability and durability.

Tj Introduction:

The TJ Wrangler was introduced for the 1997 model year, replacing the YJ generation. It marked a significant return to the classic CJ-style round headlights and coil-spring suspension.

Tj Updates 2005:

The 2005 model year brought significant updates, including a new interior with improved ergonomics and materials, a revised dashboard, and optional Rubicon features like Dana 44 rear axle and electronic-locking differentials becoming more widely available.

Assembly Location:

Toledo, Ohio, USA

Tj Production Years:

1997-2006 (this manual covers the final years of production for the TJ platform).

🏆 Awards & Recognition

Off Road Acclaim:

Consistently praised by off-road publications and enthusiasts for its class-leading capability.

Resale Value:

Known for strong resale value due to its enduring popularity and capability.