🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Model Generation:

TJ

Model Year:

2004

Drivetrain:

4x4

Steering Position:

Right Hand Drive (RHD)

Vin Code Start:

1 J

Vin Code End:

M

👋 Introduction

Vehicle Segment:

Compact SUV / Off-road vehicle

Target Audience:

Off-road enthusiasts, adventure seekers, DIY mechanics, owners prioritizing durability and capability.

Key Competitors:

Toyota Land Cruiser (older generations), Suzuki Samurai, Land Rover Defender (older generations), Ford Bronco (older generations).

Off Road Capability:

Renowned for its solid front and rear axles, 4x4 capability, and robust chassis.

Body Style:

Two-door convertible with removable soft top or hardtop options.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

Estimated Page Count:

1500+

Technical Scope:

Comprehensive Diagnostic and Repair Procedures

📖 Manual Coverage

Engine Management:

Engine mechanical, fuel system, ignition system, emission controls, cooling system, lubrication system, engine diagnostics.

Transmission Drivetrain:

Manual and Automatic Transmission (e.g., NV3550, NP241J '241' transfer case), Clutch, Driveshafts, Axles (Dana 30 front, Dana 35c rear).

Suspension Steering:

Front and Rear Suspension (Solid Axles, Coil Springs, Control Arms), Steering System (Power Steering Pump, Gearbox, Linkage).

Brakes:

Front Disc Brakes, Rear Disc or Drum Brakes, Anti-lock Braking System (ABS) if equipped, Parking Brake.

Electrical Electronics:

12V Battery System, Charging System (Alternator), Starting System, Lighting System, Wiper/Washer System, Instrument Cluster, Body Control Module (BCM), Powertrain Control Module (PCM), Fuses and Relays, Power Distribution.

Body Chassis:

Body structure, Doors, Hood, Tailgate, Bumpers, Seats, Interior Trim, Chassis components, Corrosion Protection.

Heating Ventilation Ac:

HVAC System, Air Conditioning, Heater Core, Blower Motor.

Maintenance Tasks:

Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs (coolant, brake fluid, power steering fluid, transfer case fluid, axle fluid), tire rotation and inspection, battery maintenance, brake pad and rotor replacement.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, circuit testing, component testing.

Repair Tasks:

Engine tune-ups, cylinder head removal/installation, piston and connecting rod service, crankshaft service, transmission overhaul, clutch replacement, transfer case repair, differential service, axle seal replacement, suspension component replacement (shocks, springs, bushings), brake caliper and rotor replacement, power steering pump and gearbox replacement, starter and alternator replacement, fuel pump replacement, radiator and water pump replacement.

Electrical Repairs:

Wiring diagrams, component testing and replacement (sensors, actuators, switches), fuse and relay identification and replacement, diagnostic tool usage.

Depth Of Coverage:

Detailed step-by-step instructions with torque specifications, clearance measurements, and diagnostic parameters.

Diagnostic Tools:

Includes guidance on using common OBD-II scan tools for diagnosis.

Special Tools:

Highlights required special tools for specific repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (Text-searchable content)

Printable:

Yes (Printable pages for offline use)

Image Resolution:

High-resolution for clear diagrams and illustrations.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code:

3.7L PowerTech I6 (242ci)

Displacement:

3.7 Liters (226 cubic inches)

Cylinders:

Inline-6

Bore X Stroke:

3.78 in x 3.13 in (96 mm x 80 mm)

Compression Ratio:

8.8:1

Valve Train:

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

Horsepower:

202 hp @ 5200 RPM

Torque:

235 lb-ft @ 4000 RPM

Fuel Delivery:

Sequential Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

87 (Octane rating may vary by region/manufacturer recommendation)

Ignition System:

Distributorless Ignition System (DIS) with individual ignition coils.

🔧 Transmission

Transmission Type:

NV3550 5-Speed Manual Transmission

Transmission Type:

42RLE 4-Speed Automatic Transmission

Transfer Case:

NV241 '241' Command-Trac Part-Time 2-Speed Transfer Case

Gear Ratios Manual Nv3550:

1st: 4.11, 2nd: 2.17, 3rd: 1.35, 4th: 1.00, 5th: 0.77

Gear Ratios Auto 42Rle:

1st: 2.80, 2nd: 1.53, 3rd: 1.00, 4th: 0.69

Fluid Type:

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

Manual Transmission Capacity:

Approx. 2.3 Liters (2.4 Quarts)

Automatic Transmission Capacity:

Approx. 7.7 Liters (8.1 Quarts)

Transfer Case Capacity:

Approx. 1.6 Liters (1.7 Quarts)

Fluid Type:

Mopar NV241 Transfer Case Lubricant (or equivalent SAE 75W-90 synthetic gear oil)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

150.9 inches (3833 mm)

Width:

66.5 inches (1689 mm)

Height:

71.4 inches (1813 mm)

Ground Clearance:

Approx. 10.5 inches (267 mm)

Curb Weight Manual:

Approx. 3,350 lbs (1519 kg)

Curb Weight Automatic:

Approx. 3,450 lbs (1565 kg)

Gross Vehicle Weight Rating:

Approx. 4,500 lbs (2041 kg)

Cargo Volume Behind Rear Seat:

Approx. 17.0 cu ft (0.48 m³)

Cargo Volume With Rear Seat Folded:

Approx. 37.0 cu ft (1.05 m³)

🛡️ Safety Features

NHTSA Rollover Resistance:

4/5 stars (for manual transmission variants)

Braking System:

Front vented disc, rear disc (standard on most TJ models for 2004), with optional ABS.

ABS Availability:

Optional on most models.

Airbags:

Driver and front passenger airbags.

Seat Belts:

3-point front seat belts, lap belts in rear.

Sport Bar:

Integral sport bar with wrap-around padding.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional premium audio with subwoofer.

Instrument Cluster:

Analog gauges for speedometer, tachometer, fuel level, and engine temperature. Warning lights for various systems.

ABS:

Optional Anti-lock Braking System (ABS) on front wheels and rear wheels.

Power Windows Locks:

Optional on most models, typically found on higher trim levels or as dealer-installed accessories.

🔧 Maintenance

Engine Oil Change:

Every 3,750 miles (6,000 km) or 3 months, whichever comes first, under normal driving conditions. Every 3,000 miles (4,800 km) or 3 months under severe conditions.

Engine Oil Filter:

Replace with each oil change.

Air Filter:

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

Spark Plugs:

Replace every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (refer to manual).

Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months.

Brake Fluid Flush:

Every 30,000 miles (48,000 km) or 24 months.

Transmission Fluid Change Manual:

Every 30,000 miles (48,000 km) or 24 months.

Transmission Fluid Change Automatic:

Every 30,000 miles (48,000 km) or 24 months. Inspect more frequently for towing or off-road use.

Transfer Case Fluid Change:

Every 30,000 miles (48,000 km) or 24 months.

Axle Fluid Change:

Every 30,000 miles (48,000 km) or 24 months, especially after submersion in water.

Engine Oil Type:

SAE 10W-30 API Service SG or higher

Engine Oil Capacity:

Approx. 5.0 Quarts (4.7 Liters) with filter change

Coolant Type:

Chrysler/Mopar OAT (Orange) Antifreeze/Coolant (5 year/100,000 mile formula) or equivalent.

Coolant Capacity:

Approx. 9.5 Quarts (9.0 Liters)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Mopar Power Steering Fluid or equivalent ATF+4.

Common Problems Engine:

Oil filter housing leaks, exhaust manifold cracks (especially with the 4.0L), crankshaft position sensor failures.

Common Problems Transmission:

NV3550 clutch throw-out bearing noise, occasional clutch chatter. 42RLE may experience harsh shifting.

Common Problems Suspension Steering:

Worn control arm bushings, loose steering box mounting, 'death wobble' (severe shimmy at speed, often related to worn steering/suspension components).

Common Problems Electrical:

Corroded grounds, failing clock spring in steering wheel, fuel pump relay failures.

Common Problems Body:

Leaks around windshield frame and door seals, door hinge wear, rust on floor pans and rocker panels.

📚 Vehicle History

Jeep Legacy:

Jeep's heritage dates back to World War II with the Willys MB, establishing a long-standing reputation for ruggedness and off-road prowess.

Tj Introduction:

The TJ Wrangler was introduced for the 1997 model year, replacing the YJ generation. It marked a significant return to coil springs and solid front axles, a departure from the YJ's leaf springs.

Tj Enhancements 2004:

The 2004 model year saw minor updates, including the introduction of the 3.7L PowerTech V6 as the standard engine, replacing the aging 4.0L inline-6 in some configurations and regions, though the 4.0L remained a popular option. Updates also included revised interior trim and potential minor exterior styling tweaks.

Production Period:

1997-2006

Assembly Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Recognition:

Consistently ranked among the top off-road capable vehicles by automotive publications and enthusiasts.

Consumer Reports Reliability:

Reliability ratings vary by model year and specific components, but the TJ generally received average to above-average ratings for its class.

Emissions Standards:

Meets applicable EPA emissions standards for the 2004 model year.