2004 Jeep Wrangler Workshop Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Platform: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Key Differentiator: Iconic off-road...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Platform:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Key Differentiator:

Iconic off-road capability, open-air design

Competitive Analysis

Competitors 2004:

Toyota 4Runner, Nissan Xterra, Ford Explorer, Chevrolet Blazer

Key Features

Body Styles:

2-Door (Wrangler), 4-Door (Wrangler Unlimited - introduced in 2004)

Powertrain Options:

Robust 4.0L Inline-6, efficient 2.4L Inline-4

Off Road Features:

Solid axles, low-range 4WD transfer case, high ground clearance, removable doors and top

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Workshop Repair

Page Count

Estimated Pages:

1500-2000

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital PDF (Searchable, Printable)

📖 Manual Coverage

Systems Covered

Engine:

4.0L (12-valve OHV Inline-6) PowerTech, 2.4L (16-valve DOHC Inline-4) DOHC

Transmission:

NV3550 (5-speed Manual), 42RLE (4-speed Automatic)

Drivetrain:

NP231 (Command-Trac NV241OR for Rubicon) Transfer Case, Dana 30 (Front Axle), Dana 35C (Rear Axle, optional Dana 44 for Rubicon)

Suspension:

Front: Solid Live Axle with Coil Springs, Radius Arms; Rear: Solid Live Axle with Coil Springs, Trailing Arms, Panhard Bar

Steering:

Recirculating Ball, Power Assist

Brakes:

Front: Ventilated Disc; Rear: Solid Disc (ABS Optional)

Electrical:

Charging System, Starting System, Ignition System, Lighting, Gauges, Body Control Module (BCM), Powertrain Control Module (PCM), Fuses and Relays, Diagnostics

Body:

Body Panels, Doors, Hood, Tailgate, Soft Top, Hardtop, Interior Trim, Bumpers

HVAC:

Heating, Ventilation, Air Conditioning System

Safety Systems:

Airbags (Driver and Passenger), Seatbelts, ABS (if equipped)

Procedures Included

Scheduled Maintenance:

Oil Changes, Filter Replacements, Tire Rotations, Fluid Checks and Replacements

Troubleshooting:

Diagnostic Charts, Symptom-Based Troubleshooting Guides

Repair Procedures:

Engine Removal/Installation, Transmission Overhaul, Axle Service, Brake Caliper Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Repair

Diagnostics:

OBD-II Diagnostic Trouble Codes (DTCs), Scan Tool Usage, Component Testing Procedures

Wiring Diagrams:

Complete Electrical Schematics for all Systems

Specifications:

Torque Specifications, Fluid Capacities, Component Dimensions, Electrical Values

Rebuilds:

Engine Rebuild Specifications, Transmission Rebuild Procedures, Differential Rebuild Procedures

Technical Depth

Depth:

In-depth, Professional-Level Technical Information

Detail Level:

Includes detailed diagrams, schematics, step-by-step instructions, and diagnostic procedures

Target Audience:

Professional Technicians and Advanced DIY Mechanics

📊 Manual Specifications

File Format

File Type:

Searchability:

Full text searchable

Printability:

Printable

Print Quality

Image Resolution:

High-resolution, clear diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Name 1:

4.0L PowerTech Inline-6

Engine Code 1:

Displacement 1:

3952 cc (241 cubic inches)

Configuration 1:

Inline-6 Cylinder, OHV, 12 Valves

Bore X Stroke 1:

98.4 mm x 86.6 mm (3.87 in x 3.41 in)

Compression Ratio 1:

8.8:1

Horsepower 1:

190 hp @ 4600 rpm

Torque 1:

235 lb-ft @ 3200 rpm

Performance

Engine Name 2:

2.4L DOHC Inline-4

Engine Code 2:

Displacement 2:

2429 cc (148 cubic inches)

Configuration 2:

Inline-4 Cylinder, DOHC, 16 Valves

Horsepower 2:

147 hp @ 5400 rpm

Torque 2:

165 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 AKI (for 4.0L), 87 AKI (for 2.4L)

🔧 Transmission

Standard

Transmission Type Std:

NV3550 5-Speed Manual

Optional

Transmission Type Opt:

42RLE 4-Speed Automatic

Features

Clutch Type:

Hydraulic Actuated Dry Single Plate

Manual Fluid Spec:

Mopar Manual Transmission Fluid (or equivalent SAE 75W-90 synthetic gear oil)

Automatic Fluid Spec:

Mopar ATF+4 (MS-9602)

📐 Dimensions

Exterior

Wheelbase 2Dr:

93.4 inches (2372 mm)

Wheelbase 4Dr Unlimited:

103.4 inches (2626 mm)

Length 2Dr:

150.7 inches (3828 mm)

Length 4Dr Unlimited:

161.7 inches (4107 mm)

Width Excluding Mirrors:

66.5 inches (1689 mm)

Height To Top Of Hardtop:

72.5 inches (1841 mm)

Ground Clearance:

Approx. 8.3 inches (211 mm) - varies by tire size and configuration

Weights

Curb Weight 2Dr Manual:

Approx. 3,275 lbs (1485 kg)

Curb Weight 2Dr Auto:

Approx. 3,350 lbs (1520 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4,400 - 4,800 lbs (2000 - 2177 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star (may vary by configuration)

Active Features

Optional Anti-lock Braking System (ABS) on all 4 wheels

Traction Control:

Not standard, part of optional traction control system for some models/trims

Passive Features

Airbags:

Driver and front-passenger airbags

Seatbelts:

Three-point seat belts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Optional premium audio systems with CD player, AM/FM stereo

Navigation:

Not typically factory-equipped in 2004, aftermarket options available

Driver Assistance

Cruise Control:

Optional

Connectivity

Auxiliary Input:

Not standard, aftermarket solutions

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions (refer to manual for specifics)

Tire Rotation Interval:

Every 5,000-7,500 miles (8,000-12,000 km)

Engine Air Filter Replacement:

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

Spark Plug Replacement 4.0L:

Approx. 100,000 miles (160,000 km) for platinum-tipped plugs

Fluid Specifications

Engine Oil Capacity 4.0L:

4.0 quarts (3.8 liters) with filter

Engine Oil Type 4.0L:

SAE 10W-30 (API SJ or higher)

Coolant Capacity:

Approx. 10.5 quarts (9.9 liters)

Coolant Type:

Mopar Antifreeze/Coolant (5/150 Formula) or equivalent OAT/HOAT coolant

Brake Fluid Type:

DOT 3

Known Issues

Common Issue 1:

Oil filter adapter housing leaks (common on 4.0L)

Common Issue 2:

Radiator leaks/cracks

Common Issue 3:

Sway bar disconnect issues (on Rubicon models)

Common Issue 4:

Cracked exhaust manifolds (common on 4.0L)

Common Issue 5:

Door seal leaks and water ingress

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Descended from WWII Willys MB, known for ruggedness and off-road prowess

Model Evolution

Tj Generation Intro:

1997 (This generation ran from 1997-2006)

Key Tj Changes 2004:

Introduction of the 4-door Wrangler Unlimited

Production

Manufacturing Plant:

Toledo North Assembly, Toledo, Ohio, USA