Segment:
Compact SUV / Off-road Vehicle
Key Competitors:
Toyota 4Runner, Ford Bronco (earlier generations), Nissan Xterra
Vehicle Identity:
Iconic off-road capability, removable doors and roof, robust solid axle suspension (front and rear for most TJ models).
Benefits:
Provides comprehensive factory-level repair and maintenance information, empowering owners and technicians to perform a wide range of tasks, saving time and money compared to dealership service.
Powertrain:
Engine, Transmission (Automatic & Manual), Transfer Case, Drivetrain, Fuel System, Exhaust System
Chassis:
Suspension (Front & Rear), Steering, Brakes (ABS & Non-ABS), Wheels & Tires
Body & Electrical:
Body Panels, Interior Trim, HVAC, Electrical System, Lighting, Wiring Diagrams, Body Control Module (BCM), Audio System
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections
Repair:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper servicing, electrical component diagnosis and repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing
Special Tools:
Identification and usage of specialized tools required for specific procedures
Body And Frame:
Body panel removal and installation, door and top mechanisms, interior trim, chassis and frame inspection and repair, rust repair guidance.
Suspension And Steering:
Ball joint replacement, control arm Bushing replacement, shock absorber and spring replacement, steering gear diagnosis and repair, track bar and linkage replacement.
Brakes:
Front and rear brake pad and rotor replacement, caliper service, brake line and hose replacement, ABS system bleeding and component testing.
Electrical System:
Detailed wiring diagrams for all circuits, starter, alternator, battery, ignition system, lighting, power windows, power locks, gauges, and computer diagnostics.
Depth:
Comprehensive: from basic fluid checks to full engine and transmission rebuilds. Includes detailed specifications, torque values, and component removal/installation procedures.
Engine Rebuild:
Complete engine disassembly, inspection, cleaning, measurement, machining specifications, and reassembly procedures for both 4.0L I6 and 4-cylinder engines.
Transmission Rebuild:
Detailed overhaul procedures for the 42RLE automatic transmission and the NV3550 manual transmission, including clutch assembly and torque converter replacement.
Chassis Components:
Axle bearing and seal replacement, differential service, wheel bearing replacement, U-joint replacement.
Engine Code 1:
4.0L I6 (High Output) - HO
Engine Displacement 1:
242 cu in (3952 cc)
Engine Configuration 1:
Inline 6-Cylinder, Overhead Valve (OHV)
Bore X Stroke 1:
3.875 in x 2.875 in (98.4 mm x 73.0 mm)
Compression Ratio 1:
8.7:1
Horsepower 1:
190 hp @ 4,600 rpm
Torque 1:
235 lb-ft @ 3,200 rpm
Fuel Delivery 1:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type 1:
Unleaded Gasoline
Engine Code 2:
2.5L I4 (97-02) / 2.4L I4 (03-06) - PowerTech
Engine Displacement 2:
150 cu in (2464 cc) / 147 cu in (2413 cc)
Engine Configuration 2:
Inline 4-Cylinder, Single Overhead Cam (SOHC)
Horsepower 2:
118-147 hp (depending on year and exact engine)
Torque 2:
145-160 lb-ft (depending on year and exact engine)
Wheelbase:
93.4 inches (2372 mm)
Length:
151.4 inches (3845 mm)
Width:
66.5 inches (1689 mm)
Height:
71.0 inches (1803 mm)
Exterior Long Wheelbase Lj
Wheelbase:
103.4 inches (2626 mm)
Length:
167.2 inches (4247 mm)
Curb Weight Approx:
3,400 - 4,000 lbs (1542 - 1814 kg)
Gross Vehicle Weight Rating Approx:
4,500 - 5,000 lbs (2041 - 2268 kg)
NHTSA Rollover Resistance:
3-Star (due to high center of gravity inherent to SUVs)
Braking System:
Front Disc / Rear Drum (standard), Optional Front & Rear Disc with ABS
Traction Control:
Optional on some later models
Airbags:
Driver and Passenger Front Airbags
Rollover Protection:
Integral sport cage (internal roll bar structure)
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 specific recommendation based on oil type).
Tire Rotation:
Every 5,000 - 7,500 miles (8,000 - 12,000 km)
Engine Coolant Flush:
Every 30,000 miles (48,000 km) or 2-3 years
Spark Plug Replacement:
Approximately 100,000 miles (160,000 km) for the 4.0L I6 with distributorless ignition (1997 onwards models often used platinum or iridium plugs).
Engine Oil 4.0L I6:
API SG or higher, SAE 10W-30 (refer to manual for seasonal variations and synthetic options)
Transmission Fluid 42Rle Auto:
ATF+4 (MS-9602)
Transmission Fluid Nv3550 Manual:
API GL-3 or GL-4, SAE 75W-90 (some sources recommend specific Mopar fluid)
Transfer Case Fluid Nv231/Nv241Or:
Mopar NV241 Transfer Case Lubricant or equivalent SAE 5W-30
Coolant:
Mopar Antifreeze/Coolant (HOAT) or equivalent, 50/50 mix with distilled water
Power Steering Fluid:
ATF+4 (MS-9602) or Mopar Power Steering Fluid
Common Issues List:
Cracked exhaust manifolds (4.0L I6), rear main seal leaks (4.0L I6), NP231 transfer case chain stretch, automatic transmission (42RLE) solenoid issues, ball joint wear, steering box wear, evaporator core leaks (HVAC), rust (especially frame and floor pans).
Jeep Legacy:
Direct descendant of the original Willys MB military Jeep, known for ruggedness and off-road prowess since WWII.
Tj Introduction:
Introduced for the 1997 model year, replacing the YJ Wrangler. Key innovation was the coil spring suspension replacing the YJ's leaf springs, significantly improving ride quality and articulation.
Rubicon Introduction:
The Rubicon trim was introduced in 2003, featuring Dana 44 axles front and rear, a 4:1 low-range gear ratio in the transfer case (Rock-Trac), electronically locking front and rear differentials, and a front anti-roll bar disconnect system.
Lj Introduction:
The 'Unlimited' or 'LJ' model, featuring a 103.4-inch wheelbase (a 10-inch stretch), was introduced for the 2004 model year, offering increased rear passenger legroom and cargo space.
Production Period:
1997-2006
Manufacturing Plant:
Toledo North Assembly Plant, Toledo, Ohio, USA
