🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2003-2007

Region:

US/Canada

Chassis Codes:

TJ

👋 Introduction

Segment:

Compact SUV, Off-Road Vehicle

Positioning:

Renowned for its off-road capability, ruggedness, and iconic design. A benchmark for trail-ready vehicles.

Competitors:

Toyota 4Runner, Nissan Xterra, Ford Bronco (previous generations), Suzuki Samurai/Vitara.

Design:

Removable doors, fold-down windshield, exposed roll cage, solid axles (on most models), short wheelbase for maneuverability.

Capability:

Exceptional off-road prowess with available locking differentials (Rubicon), high ground clearance, and robust four-wheel-drive systems.

Audience:

Off-road enthusiasts, adventurers, outdoor lifestyle consumers, and those seeking a durable, capable vehicle.

📋 Manual Details

Engine Coverage:

4.0L (PowerTech I6), 2.4L (PowerTech I4)

Transmission Coverage:

NV3550 5-Speed Manual, NV241OR (Rubicon Transfer Case), 42RLE 4-Speed Automatic

Chassis Systems Coverage:

Suspension, Steering, Brakes, Driveline, Transfer Case, Axles (Dana 30 Front, Dana 44 Rear/Rubicon)

Electrical Systems Coverage:

Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, Instrumentation, HVAC Controls, Audio Systems, Power Accessories, Diagnostic Trouble Codes (DTCs)

Body And Frame Coverage:

Body Panels, Doors, Hood, Tailgate, Interior Trim, Frame Inspection and Repair

Estimated Pages:

Approximately 2500+

Type:

Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

Compatibility:

Windows (95-10), Linux, macOS, iOS, Android

📖 Manual Coverage

Powertrain:

Engine mechanical (disassembly, assembly, inspection), cooling system, fuel system, ignition system, exhaust system, engine diagnostics and troubleshooting.

Drivetrain:

Manual and automatic transmission service, transfer case operation and repair, driveshaft balancing and U-joint replacement, front and rear axle service (including differential rebuilds and gear ratio adjustments for Rubicon models).

Braking System:

Front and rear brake service (disc brake pad replacement, caliper and rotor service), parking brake adjustment and repair, ABS system diagnostics and component replacement.

Steering And Suspension:

Power steering system service, steering gear inspection and repair, front and rear suspension component replacement (shocks, springs, bushings, control arms), steering linkage and stabilizer bar service.

Electrical System:

Battery and charging system, starter motor, alternator, lighting systems (headlights, taillights, interior), power windows, power locks, instrument cluster, horn, wiper system, fuse and relay identification and testing.

HVAC System:

Air conditioning system service (refrigerant charging, component replacement), heating system, blower motor, climate controls, cabin air filter replacement.

Preventive Maintenance:

Oil and filter changes, fluid level checks and top-offs, tire rotation and pressure checks, brake inspection, belt and hose inspection.

Diagnostic Procedures:

Systematic troubleshooting charts, diagnostic trouble code (DTC) retrieval and interpretation, circuit testing, component testing.

Repair Procedures:

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

Overhaul Procedures:

Detailed instructions for engine, transmission, and transfer case overhauls.

Body And Interior Repair:

Door panel removal, seat adjustment and removal, carpet replacement, minor body panel repair and alignment.

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

PDF Version:

Likely PDF 1.4 or higher, supporting searchable text and bookmarks.

Resolution:

High-resolution scans suitable for clear viewing and printing of text, diagrams, and images.

Binding:

Not Applicable (Digital PDF)

Paper:

Not Applicable (Digital PDF)

Text Search:

Yes, searchable text allows for quick access to specific topics and procedures.

Hyperlinks:

Likely includes internal hyperlinks for easy navigation between sections and diagrams.

⚙️ Engine Specifications

Engine 1 Name:

4.0L PowerTech I6

Engine 1 Displacement:

3960 cc (242 cubic inches)

Engine 1 Bore X Stroke:

3.875 x 3.56 inches

Engine 1 Compression Ratio:

8.8:1

Engine 1 Horsepower:

190 hp @ 4600 rpm (approx.)

Engine 1 Torque:

235 lb-ft @ 3200 rpm (approx.)

Engine 1 Block Material:

Cast Iron

Engine 1 Cylinder Head Material:

Aluminum

Engine 1 Fuel Delivery:

Multi-port Fuel Injection (MPI)

Engine 1 Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug or coil rail.

Engine 2 Name:

2.4L PowerTech I4

Engine 2 Displacement:

2429 cc (148 cubic inches)

Engine 2 Horsepower:

150 hp @ 5200 rpm (approx.)

Engine 2 Torque:

170 lb-ft @ 3800 rpm (approx.)

Engine 2 Fuel Delivery:

Multi-port Fuel Injection (MPI)

0 60 Mph 4.0L:

Approximately 8.5 - 9.5 seconds

0 60 Mph 2.4L:

Approximately 11.0 - 12.0 seconds

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane (Minimum)

🔧 Transmission

Transmission Type Standard:

NV3550 5-Speed Manual Transmission

Transmission Type Optional:

42RLE 4-Speed Automatic Transmission

Transfer Case:

NV241 GII (Command-Trac) part-time 2-speed, or NV241OR (Rock-Trac) with 4:1 low range for Rubicon models.

Manual Gear Ratios Nv3550:

1st: 4.01, 2nd: 2.32, 3rd: 1.47, 4th: 1.00, 5th: 0.77, Reverse: 3.58

Automatic Gear Ratios 42Rle:

1st: 2.804, 2nd: 1.529, 3rd: 1.000, 4th: 0.742, Reverse: 2.207

Manual Transmission Fluid:

MS-9224 (or equivalent spec) SAE 75W-90 Synthetic Gear Lubricant

Automatic Transmission Fluid:

ATF+4 (MS-9602 or equivalent spec)

Transfer Case Fluid:

MS-9476 (or equivalent spec) ATF+4 or NP241 Service Fill Fluid

📐 Dimensions

Wheelbase 2 Door:

93.4 inches

Wheelbase 4 Door Unlimited:

103.4 inches (This is for LJ Unlimited models, not standard 2-door TJ)

Length 2 Door:

151.3 inches

Width Without Doors:

66.7 inches

Height To Hardtop:

71.9 inches

Ground Clearance Rubicon:

10.1 inches

Curb Weight Approx 2 Door:

3750 - 4100 lbs

Towing Capacity:

2000 lbs

Payload Capacity:

800 - 900 lbs

🛡️ Safety Features

NHTSA Rollover Resistance:

3 out of 5 stars (two-door models are inherently more prone to rollovers due to higher center of gravity).

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Not widely available or standard on this generation.

Airbags:

Driver and passenger front airbags.

Rollover Protection:

Integral sport bar (roll cage) integrated into the B-pillars and windshield frame.

💡 Technology Features

Audio Systems:

Factory AM/FM/CD players, optional Infinity premium audio systems with subwoofer. Base models may have basic AM/FM/Cassette.

Navigation:

Aftermarket navigation systems are common. Factory navigation was not typically offered on the TJ generation.

Cruise Control:

Available on higher trim levels.

Tire Pressure Monitoring:

Not standard on this generation.

Auxiliary Input:

Aftermarket head units typically offer auxiliary inputs or USB ports. Factory systems may not have these.

🔧 Maintenance

Oil Change Interval Severe:

3,000 miles or 3 months

Oil Change Interval Normal:

5,000 miles or 6 months

Engine Air Filter Replacement:

Every 15,000 miles or 12 months (more often in dusty conditions)

Cabin Air Filter Replacement:

Every 12,000 - 15,000 miles or 12 months (if equipped)

Spark Plug Replacement 4.0L:

Approx. 100,000 miles (refer to specific spark plug type for exact interval)

Coolant Flush:

Every 30,000 miles or 24 months

Engine Oil Type 4.0L:

API SG or SH, SAE 10W-30 (or SAE 5W-30 for extreme cold weather)

Engine Oil Capacity 4.0L:

6.0 US quarts (5.7 liters) with filter

Engine Oil Type 2.4L:

API SG or SH, SAE 5W-30

Engine Oil Capacity 2.4L:

5.0 US quarts (4.7 liters) with filter

Coolant Type:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, meeting MS-9769 specification. Typically a 50/50 mix with distilled water.

Common Problem 1:

Cracking of the exhaust manifold on the 4.0L I6 engine.

Common Problem 2:

Leaks from the transfer case rear output seal and pinion seal.

Common Problem 3:

Wheel bearing failure, especially on lifted or off-road driven vehicles.

Common Problem 4:

Sway bar disconnect issues on Rubicon models (electronic disconnect mechanism).

Common Problem 5:

Oil filter housing leaks on the 4.0L I6.

📚 Vehicle History

Jeep Legacy:

Direct descendant of the original World War II Willys MB Jeep, embodying a legacy of ruggedness and off-road capability.

Tj Generation:

The TJ generation (1997-2006) marked a significant departure from the YJ with the return to round headlights and the adoption of coil springs for a vastly improved on-road ride and off-road articulation compared to leaf springs.

Updates During Generation:

Minor updates included changes to engine options, transmissions, interior amenities, and appearance packages throughout its lifespan. The 2003 model year saw significant interior and exterior styling updates.

Manufacturing Location:

Toledo, Ohio, USA

Production Years Covered:

The TJ generation ran from 1997 to 2006. This manual covers models manufactured within the 2003-2007 range, implying it might also touch upon very early JK model variations if the definition is stretched, but primarily focuses on the TJ.

🏆 Awards & Recognition

Off Road Awards:

Consistently praised by off-road publications and enthusiasts for its capability and aftermarket support.

Vehicle Awards:

Often cited as a benchmark for off-road performance and a highly customizable platform.