Segment:
Compact SUV / Off-Road Vehicle
Orientation:
Right-Hand Drive (RHD) market specific.
Competitors Era:
Suzuki Vitara, Land Rover Defender (though typically higher segment), Toyota Land Cruiser Prado (in some markets).
Iconic Design:
Classic Jeep seven-slot grille, round headlights, exposed hinges, and removable doors/top for open-air driving.
Off Road Capability:
Legendary 4x4 system (likely Command-Trac or Selec-Trac), solid front axle, short overhangs, high ground clearance.
Systems:
Engine, Transmission, Drivetrain, Brakes, Steering, Suspension, Electrical System, HVAC, Body, Chassis
Estimated Pages:
Approximately 1500+
Type:
Factory Service Manual / Repair Manual
Engine Mechanical:
Detailed component removal, installation, overhaul, and specifications for the 4.0L I6 engine.
Engine Electrical:
Ignition system, fuel system, emissions control, starting and charging systems, sensors, and ECM diagnostics.
Transmission Drivetrain:
NV3550 manual transmission, NP231 or NP241 transfer case, Dana 30 front axle, Dana 35 rear axle (likely), drivelines, and related components.
Brakes:
Front disc brakes, rear disc or drum brakes (depending on axle option), ABS (if equipped), parking brake system, hydraulic components.
Suspension Steering:
Front and rear solid axle suspension (leaf springs or coil springs depending on variant), steering system, power steering, alignment specifications.
Body Chassis:
Body panel removal and installation, frame components, bumpers, doors, hood, tailgate, interior trim, weatherstripping.
Electrical Accessories:
Lighting, wipers, power windows/locks (if equipped), audio system, instrument panel, wiring diagrams for all systems.
HVAC:
Air conditioning system, heating system, ventilation, climate controls.
Maintenance:
Routine oil changes, filter replacements, fluid checks and changes, belt inspection and replacement, spark plug service.
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, and mechanical failures using symptom-based approaches and diagnostic charts.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all systems.
Diagnostics:
On-board diagnostic (OBD-II) system operation, fault code retrieval, and diagnostic flowcharts.
Depth:
Comprehensive, covering from basic owner maintenance to full engine and transmission overhauls, including detailed torque specifications and clearances.
Engine Code:
4.0L I6 (Power Tech)
Displacement:
3952 cc (241 cubic inches)
Configuration:
Inline 6-cylinder, Overhead Valve (OHV)
Horsepower:
Approx. 190-200 hp @ 4600-4800 rpm (varies slightly by year/tune)
Torque:
Approx. 235-245 lb-ft @ 3200-3400 rpm (varies slightly by year/tune)
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Coolant Type:
Mopar Antifreeze/Coolant (Green) or equivalent silicate-free coolant.
Oil Type:
SAE 10W-30 or 10W-40 API SG/SH/SJ certified
Oil Capacity:
6.0 US quarts (5.7 Liters) with filter change
Transmission Type:
NV3550 5-Speed Manual Transmission
Transmission Type:
42RLE 4-Speed Automatic Transmission (less common on RHD models but possible)
Transfer Case:
NV231 Command-Trac (standard 2-speed part-time 4WD) or NV241 OR (Rubicon - not specified but potential)
Manual Transmission Fluid:
NV3550: Mopar Manual Transmission Lubricant or equivalent SAE 75W-90 API GL-3/GL-4
Automatic Transmission Fluid:
42RLE: ATF+4 (MS-9602)
Transfer Case Fluid:
NV231/241: Mopar NV241 Transfer Case Lubricant or equivalent SAE 75W-90 API GL-5
NHTSA Rollover Resistance:
Three-star rating (typical for TJ generation)
ABS:
Optional Anti-lock Braking System (ABS) - typically on rear wheels only for this era, or 4-wheel ABS on higher trims.
Airbags:
Driver and passenger front airbags.
Seat Belts:
3-point front seat belts, lap belts in rear (depending on configuration).
Frame Construction:
Body-on-frame construction for robust off-road durability.
Audio System:
Factory AM/FM/CD player (single disc or changer), optional Infinity speaker system.
Connectivity:
Limited by modern standards; typically no Bluetooth or USB connectivity from the factory. Aftermarket solutions are common.
Features:
Basic systems; cruise control, power steering. No advanced driver-assistance systems (ADAS).
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe service may require more frequent changes.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Approx. every 30,000-100,000 miles depending on spark plug type (copper vs. platinum/iridium - typically copper for original spec).
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Brake Fluid Change:
Every 24,000 miles (38,000 km) or 2 years.
Power Steering Fluid:
ATF+4 (MS-9602) or Mopar Power Steering Fluid.
Common Wear Items:
U-joints, ball joints, track bar bushings, clutch components (manual), exhaust manifold cracks (4.0L), interior trim wear, potential for rust on frame and body.
Electrical Gremlins:
Occasional issues with wiring harnesses, grounds, and modules; starter and alternator failure can occur with age.
Jeep Legacy:
Continues the lineage of military and civilian Jeep utility vehicles, known for off-road prowess and iconic design.
Tj Generation:
Introduced in 1996 as a replacement for the YJ Wrangler. The TJ generation marked a significant return to the classic CJ-style coil-spring front suspension.
Updates 2005:
The 2005 model year saw minor updates, continuing the evolution from previous TJ years. Features like the Dana 44 rear axle became more common, though Dana 35 was still prevalent.
Production Period:
TJ generation produced from 1996 to 2006.
Manufacturing Plant:
Toledo, Ohio, USA
