Vehicle Segment:
Compact SUV / Off-Road Vehicle.
Target Audience:
Enthusiasts, off-roaders, DIY mechanics, and owners seeking in-depth repair knowledge.
Primary Competitors Segment:
Bronco, Samurai (historically); later influenced crossover SUVs.
Vehicle Appeal:
Renowned off-road capability, iconic design, open-air driving experience, robust platform.
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission controls, engine electrical.
Transmission Drivetrain:
Manual transmission (NV3550), automatic transmission (42RLE), transfer case (NV241OR), clutch, driveshafts, axles, differentials.
Suspension Steering:
Front and rear suspension (solid axles, coil springs), steering system, power steering.
Brakes:
Front disc brakes, rear drum brakes (standard), Anti-lock Braking System (ABS) if equipped.
Electrical Electronics:
Battery, charging system, starting system, lighting, instruments, body control module (BCM), fuse box diagrams, wiring schematics.
Body Chassis:
Body construction, doors, panels, bumpers, interior trim, frame, exhaust system routing.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair.
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults, troubleshooting charts, symptom-based troubleshooting.
Repair Overhaul:
Complete disassembly, inspection, repair, and reassembly procedures for all major mechanical and electrical components.
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs.
Depth Of Coverage:
Factory-level technical details, including torque specifications, clearances, diagnostic trouble codes (DTCs), and repair sequences.
Digital Format:
Searchable PDF with high-resolution diagrams and images.
Image Quality:
Clear, crisp images and diagrams suitable for digital viewing and potential printing.
Binding Type Physical Analogy:
N/A (Digital Format)
Paper Type Physical Analogy:
N/A (Digital Format)
Engine Code:
3UZFE (for 4.0L V6), 425 (for 2.4L I4 - less common in US spec for 2004, but possible)
Engine Name Common:
4.0L "SOHC" V6 (PowerTech)
Valvetrain:
SOHC (Single Overhead Camshaft)
Horsepower Hp:
190 @ 4600 RPM
Torque Lb Ft:
235 @ 3200 RPM
Fuel Delivery:
Multi-Port Fuel Injection (MPFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Transmission Type Standard:
5-Speed Manual Transmission (NV3550)
Transmission Type Optional:
4-Speed Automatic Transmission (42RLE)
Transfer Case:
Command-Trac NV241OR (Part-Time, 2-High, 4-High, Neutral, 4-Low)
NHTSA Front Driver Impact:
Not Rated (Vehicle Design)
NHTSA Front Passenger Impact:
Not Rated (Vehicle Design)
IIHS Side Impact:
Acceptable
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
Front 3-point, Rear Lap and Shoulder (if equipped)
Audio System:
Factory AM/FM/CD player, optional premium sound system.
Dashboard Features:
Analog gauges, basic climate controls, optional power windows/locks.
Driver Assistance Features:
Limited; primarily focused on mechanical reliability and off-road capability. ABS optional.
Connectivity Options:
Minimal. Basic power outlets.
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (synthetic oil may extend).
Engine Air Filter Replacement:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement:
Every 30,000-60,000 miles (depending on plug type).
Engine Oil Type:
SAE 5W-30 (API Certified)
Engine Oil Capacity Quarts:
5.0 (with filter)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) - Pink Color
Transmission Fluid Type Manual:
Mopar Manual Transmission Lubricant (or equivalent) - NV3550 specific.
Transmission Fluid Type Automatic:
ATF+4 (MS-9602)
Transfer Case Fluid Type:
Mopar NV241OR Transfer Case Lubricant (or equivalent, e.g., SAE 75W-85 GL-5)
Differential Fluid Type:
SAE 75W-90 (GL-5) - consider limited-slip additive if applicable.
Common Problems:
Radiator leaks, heater core issues, exhaust manifold cracks (4.0L), clutch wear, axle seal leaks, steering box wear, "death wobble" (suspension/steering linkage issues).
Maintenance Focus Areas:
Regular inspection of suspension components, steering linkages, and drivetrain seals is crucial.
