Market Position:
The 2004 Jeep Wrangler TJ represents a highly capable and iconic off-road vehicle, known for its ruggedness and go-anywhere attitude. This service manual positions itself as an essential tool for owners and independent mechanics seeking to maintain and repair this specialized vehicle.
Competitive Analysis:
While direct competitors in the off-road SUV segment existed, the Wrangler's unique open-air design, solid axles (on earlier models like the TJ), and distinct styling set it apart. This manual caters to a niche but dedicated enthusiast base.
Key Features:
Focus on off-road capability, robust construction, iconic design, and a strong aftermarket support community.
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Fuel System, Cooling System, Exhaust System, Body & Chassis, Interior Trim, Diagnostics
Estimated Page Count:
Approximately 1000+
Manual Type:
Workshop Service and Repair Manual
Format:
Digital (likely PDF)
Engine Mechanical:
Detailed overhaul procedures, component specifications, timing, valve adjustments, cooling system, lubrication system.
Fuel And Emissions:
Fuel injection system diagnostics, fuel pump, injectors, EVAP system, emissions controls.
Transmission Drivetrain:
Manual and automatic transmission overhaul, transfer case service, axle inspection and repair, driveshaft, U-joints.
Suspension Steering:
Front and rear suspension components, alignment specifications, steering gear, power steering system.
Brakes:
Front and rear brake systems (disc/drum), ABS diagnostics, hydraulic system, parking brake.
Electrical System:
Battery, charging system, starting system, ignition system, lighting, fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs).
HVAC:
Air conditioning system, heating system, blower motor, climate control diagnostics.
Body Chassis:
Body panel removal/installation, interior trim, exterior trim, doors, hood, tailgate, frame components.
Maintenance:
Regular scheduled maintenance, fluid checks and changes, filter replacements, lubrication points.
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble code (DTC) interpretation, symptom-based diagnostics.
Repair:
Step-by-step repair instructions for all major vehicle systems, including component removal, overhaul, and reinstallation.
Wiring Diagrams:
Detailed electrical system wiring diagrams for various circuits and components.
Technical Depth:
Comprehensive, covering everything from basic maintenance tasks to full engine and transmission rebuilds, including advanced diagnostic procedures.
Engine Code:
4.0L Straight-6 (High Output)
Engine Displacement:
3952 cc (241 cubic inches)
Engine Configuration:
Inline 6-cylinder, Overhead Valve (OHV)
Horsepower:
190 hp @ 4,400 rpm
Torque:
235 lb-ft @ 3,200 rpm
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Block Material:
Cast Iron
Cylinder Head Material:
Cast Iron
Bore X Stroke:
3.88 in x 3.41 in (98.5 mm x 86.7 mm)
Transmission Type:
NV3550 5-Speed Manual Transmission
Transmission Type:
42RLE 4-Speed Automatic Transmission
Transfer Case:
NV241OR 'Rock-Trac' (Rubicon models) or NV231 'Command-Trac' (Sport, Sahara models)
Gear Ratios Manual:
3.75:1 (1st), 2.17:1 (2nd), 1.36:1 (3rd), 1.00:1 (4th), 0.78:1 (5th), 3.42:1 (Reverse)
Gear Ratios Automatic:
2.80:1 (1st), 1.53:1 (2nd), 1.00:1 (3rd), 0.71:1 (4th)
Manual Transmission Fluid:
MS-9224 Chrysler Specification (e.g., Mopar Manual Transmission Lubricant, synthetic)
Automatic Transmission Fluid:
MS-9602 Chrysler Specification (ATF+4)
Transfer Case Fluid:
MS-9224 Chrysler Specification (e.g., Mopar Manual Transmission Lubricant, synthetic)
NHTSA Frontal Crash Test:
Driver: 4 Stars, Passenger: 4 Stars (2004 Model Year)
NHTSA Side Impact Crash Test:
Front Driver: 5 Stars, Front Passenger: 5 Stars (2004 Model Year)
Active Features:
Four-wheel Anti-lock Brakes (ABS)
Passive Features:
Driver and front passenger airbags, seatbelt pretensioners.
Infotainment System:
Basic AM/FM stereo with CD player. Optional Infinity speaker system available.
Driver Assistance Features:
Limited; primarily focused on core driving dynamics. ABS is the main active safety feature.
Connectivity Features:
No integrated Bluetooth or USB ports as standard. Aftermarket solutions are common.
Oil Change Interval:
Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first, using synthetic oil. Refer to manual for specific conditions.
Tire Rotation Interval:
Every 5,000 to 7,500 miles (8,000 to 12,000 km)
Transmission Fluid Change:
Every 30,000 to 60,000 miles (48,000 to 96,000 km), depending on usage (e.g., heavy towing, off-roading).
Engine Oil Capacity:
6 US quarts (5.7 liters) with filter (4.0L engine)
Engine Oil Type:
SAE 10W-30 (synthetic recommended for extreme temperatures)
Coolant Type:
Chrysler OAT (Organic Additive Technology) or HOAT (Hybrid OAT) - typically a 50/50 mix of antifreeze and distilled water. Refer to manual for exact specification (e.g., MS-9769).
Common Issues:
Coolant leaks (heater core, radiator), exhaust manifold cracks (4.0L engine), rear main seal leaks, track bar wear, and sway bar end link issues. Clutch wear on manual transmissions.
Brand Heritage:
Jeep has a long and storied history dating back to World War II, with its lineage directly tied to military utility vehicles. This heritage imbues the Wrangler with an authentic off-road DNA.
Model Evolution:
The 2004 Wrangler is part of the TJ generation (1997-2006), which marked a significant departure from its leaf-sprung predecessor (YJ) by adopting coil springs and coil-over-shock suspension for improved ride quality and articulation. The TJ also reintroduced the iconic round headlights.
Production Location:
Toledo, Ohio, USA
