🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2004

Chassis Code:

TJ

Engine Code Primary:

4.0L Inline-6 (MPI)

👋 Introduction

Vehicle Segment:

Compact Sport Utility Vehicle (SUV), known for off-road capability and open-air driving experience.

Target Audience:

Enthusiasts, off-roaders, recreational users, and those seeking a robust, utilitarian vehicle.

Competitors 2004:

Toyota Tacoma (off-road focused), Suzuki Vitara, Nissan Xterra, Ford Bronco (earlier models), Land Rover Defender (global).

Design Philosophy:

Body-on-frame construction, solid front and rear axles, removable doors and roof (soft top or hard top options).

Off Road Capability:

Part-time 4WD system with low-range gearing, high ground clearance, excellent approach/departure angles.

Powertrain Options:

Renowned 4.0L 'PowerTech' inline-six engine, offering strong torque for off-road and towing.

📋 Manual Details

Coverage Focus:

Factory Service and Repair

Estimated Pages:

1000+

Type:

Factory Service Manual (FSM)

Language:

English

Format:

WinRAR (Digital Archive) / PDF

📖 Manual Coverage

Engine:

4.0L PowerTech Inline-6 (MPI), diagnostic procedures, internal components, lubrication, cooling system, fuel system, ignition system, exhaust system, emissions control.

Transmission:

NV3550 5-Speed Manual Transmission; 42RLE 4-Speed Automatic Transmission: overhaul, diagnostics, clutch, torque converter, shift controls, fluid specifications.

Drivetrain:

Dana 30 (Front Axle), Dana 35c (Rear Axle) or optional Dana 44 (Rear Axle) differentials, transfer case (NV241 GII/241 DHD), driveshafts, U-joints, axle shafts, lubrication, bearing adjustment.

Suspension:

Front Solid Live Axle (Dana 30), Rear Solid Live Axle (Dana 35c/44), coil springs, shock absorbers, track bars, sway bars, control arms, bushing replacement, alignment specifications.

Steering:

Power steering system, steering gearbox, tie rod ends, steering column, alignment specifications, troubleshooting.

Brakes:

Front vented disc brakes, rear disc or drum brakes (depending on axle), ABS (if equipped), hydraulic system, brake fluid specifications, caliper and cylinder overhaul, bleeding procedures, parking brake.

Electrical System:

12-volt negative ground system, battery, alternator, starter motor, wiring diagrams for all circuits, lighting, fuses, relays, ignition switch, power distribution, comfort systems.

Body And Chassis:

Body construction, frame integrity, doors, hood, tailgate, windshield, body panels, interior trim, convertible top mechanisms, rust repair, paint and finish.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system: refrigerant charge, compressor, evaporator, condenser, blower motor, control panel, leak detection.

Restraint Systems:

Seat belts, airbags (if equipped): diagnostic procedures, SRS module, component replacement.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tire rotation, lubrication points, spark plug replacement.

Diagnostics:

Troubleshooting guides for common and complex issues, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, use of scan tools.

Repair:

Step-by-step repair procedures for all major vehicle systems, component removal and installation, rebuilding procedures for engines, transmissions, and axles.

Overhaul:

Detailed overhaul procedures for major components such as the 4.0L engine, manual and automatic transmissions, and front/rear axles.

Electrical Diagnostics:

Use of wiring diagrams, multimeter usage, continuity testing, voltage drop testing, troubleshooting electrical faults.

Body Repair:

Panel replacement, dent repair, welding procedures, glass replacement, convertible top repair and adjustment.

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics and specifications.

Detail Level:

Detailed exploded views, torque specifications for all fasteners, clearances and adjustments, diagnostic flowcharts.

Accuracy:

Factory authorized procedures and specifications, ensuring accuracy for professional repair and enthusiast use.

📊 Manual Specifications

File Type:

PDF (Portable Document Format) within a WinRAR archive.

Searchable:

Yes, text within PDFs is typically searchable.

Printable:

Yes, PDFs are generally printable.

Quality Descriptor:

Digital scan quality, generally high resolution suitable for screen viewing and printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Name:

4.0L PowerTech Inline-6

Displacement:

3952 cc (241 cu in)

Bore X Stroke:

98.4 mm x 86.7 mm (3.875 in x 3.414 in)

Compression Ratio:

8.8:1

Valvetrain:

Overhead Valve (OHV), 12 valves (2 per cylinder)

Block Material:

Cast Iron

Head Material:

Cast Iron

Horsepower Est:

190 hp @ 4600 rpm

Torque Est:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Regular Octane 87 (minimum)

Engine Oil Capacity:

5 quarts (4.7 liters) with filter change, SAE 10W-30 or 10W-40 (refer to manual for temperature-specific recommendations)

🔧 Transmission

Type:

NV3550 5-Speed Manual

Type:

42RLE 4-Speed Automatic

Transfer Case:

NV241 GII (Command-Trac 2-speed part-time 4WD system)

Manual Fluid:

NV3550: Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4 rated fluid, 2.5 pints)

Automatic Fluid:

42RLE: ATF+4 (MS-9602), 5.5 quarts (5.2 liters) refill

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

158.8 inches (4033 mm)

Width:

66.5 inches (1689 mm)

Height:

71.9 inches (1826 mm)

Ground Clearance:

Approx. 8.5 inches (216 mm)

Approach Angle:

Approx. 43.6 degrees

Departure Angle:

Approx. 37.4 degrees

Breakover Angle:

Approx. 25.1 degrees

Curb Weight Est:

3750 - 4100 lbs (1700 - 1860 kg), varies by trim and equipment

Towing Capacity Est:

2000 lbs (907 kg)

🛡️ Safety Features

NHTSA Front Impact:

Not explicitly rated for 2004 by NHTSA in a comparable format to modern standards; generally performed well for its era.

ABS:

Optional Anti-lock Braking System (ABS) on rear wheels or 4-wheel ABS depending on configuration.

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point seat belts in front, two-point seat belts in rear (or three-point on later models/specific trims).

Rollover Protection:

Integral sport bar (roll cage) designed for enhanced occupant protection.

💡 Technology Features

Audio System:

Base AM/FM stereo, optional CD player, optional premium Infinity sound system with amplifier.

Display:

Basic analog gauges and digital odometer display. No integrated navigation or large touchscreen displays.

Cruise Control:

Optional

Traction Control:

Optional on some models, primarily in conjunction with ABS.

Aux Input:

Not standard; aftermarket solutions often available.

Power Windows Locks:

Optional on higher trims.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions (refer to manual for detailed guidance).

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement:

Approximately every 100,000 miles (160,000 km) with recommended spark plugs (e.g., Champion Copper).

Transmission Fluid Change:

Manual: Inspect annually; Automatic: Every 30,000 - 60,000 miles (48,000 - 96,000 km), or more frequently if used for towing or off-roading.

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).

Coolant:

Mopar OAT (Orange) Antifreeze/Coolant, 50/50 mix with distilled water. Capacity: Approx. 11.4 quarts (10.8 liters).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent ATF+4.

Common Wear Items:

Clutch wear (manual), water pump leaks, starter solenoid issues, radiator leaks, exhaust manifold cracks, CV joint wear (if equipped with CV shafts).

Rear Main Seal Leaks:

Can be a concern on higher mileage 4.0L engines.

Cooling System:

Plastic radiator tanks can degrade over time; thermostat housing leaks are also reported.

Body Mount Bushings:

May degrade and require replacement to reduce noise and vibration.

Transfer Case Leaks:

Leaking seals or gaskets can occur.

📚 Vehicle History

Jeep Legacy:

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

Tj Generation:

The TJ Wrangler (1997-2006) was a significant departure from its YJ predecessor, returning to the iconic round headlights and featuring coil spring suspension for improved on-road comfort and articulation.

2004 Updates:

For 2004, minor updates included potential refinements to interior materials, sound deadening, and possibly minor option package changes.

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Awards:

The Jeep Wrangler platform consistently receives accolades from off-road publications and communities for its capability.

Consumer Reports:

Consumer Reports ratings for this era generally indicated average to below-average reliability for some components, typical of body-on-frame, off-road focused vehicles.

Emissions Certification:

Meets EPA and CARB emissions standards for its model year.