2004 Jeep Wrangler Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Codes Chassis Code: TJ Vin Code: 1"J" 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Philosophy: Renowned for...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Codes

Chassis Code:

Vin Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Philosophy:

Renowned for its legendary off-road capability and iconic design.

Competitive Analysis

Competitors:

Toyota 4Runner, Land Rover Defender (historically), Suzuki Samurai (historically).

Key Features

Distinctive Features:

Solid front and rear axles, removable doors and roof, high ground clearance, robust 4x4 system.

Target Audience:

Off-road enthusiasts, adventure seekers, outdoor lifestyle users.

📋 Manual Details

Coverage Areas

Main Coverage:

Complete service, repair, and maintenance for the 2004 Jeep Wrangler (TJ).

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Primary Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system.

Engine Performance:

Fuel injection, ignition system, emission controls, engine diagnostics.

Transmission Manual:

NV3550 (5-speed) service, repair, and overhaul.

Transmission Automatic:

42RLE (4-speed automatic) service, repair, and overhaul.

Transfer Case:

NV241OR (241OR 'Rock Trac') service and repair.

Drivetrain Axles:

Dana 30 front axle, Dana 35c or Dana 44 rear axle service, differential overhaul, axle shafts.

Brakes:

Hydraulic system, ABS, front disc brakes, rear disc brakes (if equipped), parking brake, bleeding procedures.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering linkage.

Steering:

Power steering system, steering gear, steering column, steering wheel, alignment specifications.

Electrical System:

Battery, charging system, starting system, lighting, wipers, horn, power accessories, fuses, relays.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, windshield, convertible top, soft top removal/installation.

Body Interior:

Dashboard, seats, carpets, trim panels, HVAC system components.

HVAC:

Air conditioning, heating, ventilation, climate control system diagnostics and repair.

Restraints:

Airbag system, seat belts.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, tune-ups, brake service, tire rotation.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical schematics.

Repair:

Detailed step-by-step instructions for component removal, installation, and repair.

Overhaul:

Complete engine, transmission, and axle overhaul procedures.

Diagnostics:

Using OBD-II scan tools, reading sensor data, diagnosing electrical issues.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all systems.

Technical Depth

Depth:

Comprehensive from basic owner maintenance to advanced engine rebuilds and electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content for quick information retrieval.

Printability:

Printable pages, allowing for offline use and reference.

Print Quality

Resolution:

High-resolution scans ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

3.7L V6 (JK generation began, TJ primarily used 4.0L inline-6)

Engine Type:

Inline 6-Cylinder, Overhead Valve (OHV)

Displacement:

3956 cc (241.4 cubic inches)

Bore X Stroke:

3.875 in x 3.580 in (98.4 mm x 90.9 mm)

Performance

Horsepower:

190 hp @ 4,600 rpm

Torque:

235 lb-ft @ 3,200 rpm

Fuel System

Induction:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline, 87 Octane Minimum

Engine Management

Engine Control Unit (ECU) controlled ignition and fuel.

Cooling System

Capacity:

Approx. 10.0 quarts (9.5 liters) with A/C

Lubrication

Oil Capacity:

Approx. 5.0 quarts (4.7 liters) with filter

Oil Type:

SAE 10W-30 API SJ/SL

🔧 Transmission

Standard

Transmission Type:

NV3550 5-Speed Manual Transmission

Optional

Transmission Type:

42RLE 4-Speed Automatic Transmission

Features

Clutch:

Hydraulically actuated single dry plate clutch.

Automatic Transmission Fluid:

ATF+4 (MS-9602)

Manual Transmission Fluid:

GL-3 or GL-4 (preferred) SAE 75W-90 gear oil.

Transfer Case

Transfer Case Model:

NV241OR (241OR 'Rock Trac')

Transfer Case Fluid:

NV241OR Transfer Case Fluid (Mopar specific or equivalent)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2,372 mm)

Length:

160.4 inches (4,074 mm)

Width:

73.4 inches (1,864 mm)

Height:

70.2 inches (1,783 mm) with hardtop

Ground Clearance:

Approx. 8.8 inches (224 mm)

Weights

Curb Weight:

Approx. 3,750 - 4,000 lbs (1,701 - 1,814 kg)

Gross Vehicle Weight Rating:

Approx. 4,950 lbs (2,245 kg)

Towing Capacity:

2,000 lbs (907 kg)

Wheels Tires

Standard Wheel Size:

15-inch

Standard Tire Size:

LT215/75R15 (optional LT225/75R16)

Bolt Pattern:

5x4.5 inches (5x114.3 mm)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4 out of 5 stars (Two-wheel drive), 3 out of 5 stars (Four-wheel drive)

Active Features

Anti-lock Braking System (ABS) available, typically on rear wheels only for 2004 models.

Passive Features

Airbags:

Driver and passenger front airbags.

Seat Belts:

Three-point front seat belts, lap belts for rear passengers (if equipped).

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/CD stereo system, optional Infinity sound system.

Navigation:

Not typically factory-equipped on 2004 models, aftermarket options available.

Driver Assistance

Cruise Control:

Available on most trim levels.

Connectivity

Aux Input:

Rarely factory equipped, aftermarket solutions common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on conditions.

Spark Plug Replacement:

Every 100,000 miles (160,000 km) for iridium-tipped plugs.

Coolant Flush:

Every 30,000-60,000 miles (48,000-96,000 km) or 3-5 years.

Transmission Fluid Change:

Manual: Every 60,000 miles (96,000 km). Automatic: Every 30,000-50,000 miles (48,000-80,000 km) or severe use.

Fluid Specifications

Engine Coolant:

Chrysler/Mopar Antifreeze/Coolant (MS-7170) or equivalent HOAT coolant.

Brake Fluid:

DOT 3 brake fluid.

Power Steering Fluid:

ATF+4 (MS-9602) or Chrysler power steering fluid.

Known Issues

Common Problems:

Rear main seal leaks, cracked exhaust manifolds, NP241OR chain stretch, clutch wear, death wobble (requires diagnosis and proper alignment/component replacement).

Rust Prone Areas:

Frame rails, rocker panels, floor pans, body mounts, brake lines.

📚 Vehicle History

Brand Heritage

Legacy:

Jeep's heritage dates back to WWII Willys MB, symbolizing ruggedness and off-road prowess.

Model Evolution

Tj Generation:

The TJ Wrangler (1997-2006) introduced coil springs and a significantly revised chassis over its YJ predecessor.

2004 Updates:

Minor refinements, potential package updates, but largely carried over the robust TJ platform.

Production

Assembly Location:

Toledo North Assembly Plant, Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

Consistently recognized by off-road publications and enthusiasts for its capabilities.

Ratings

Consumer Satisfaction:

Generally positive for its core purpose, though reliability can vary with maintenance and specific components.