🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Model Generation:

TJ

Year:

2004

Chassis Code:

TJ

👋 Introduction

Vehicle Type:

Compact Sport Utility Vehicle (SUV) / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, outdoor adventurers, DIY mechanics, Jeep owners seeking detailed technical information

Key Competitors 2004:

Toyota Tacoma (4-door), Nissan Xterra, Ford Escape, Suzuki Vitara

Jeep Wrangler Tj Differentiation:

Unmatched off-road capability, iconic design, solid axle front and rear suspension (most models), open-air driving experience

Design Philosophy:

Rugged, utilitarian, purpose-built for off-road performance and versatility

Body Styles:

2-door convertible (soft top, hard top options)

Off Road Systems:

Command-Trac (241 transfer case) or Selec-Trac (242 transfer case) part-time 4WD, optional Trac-Lok limited-slip differential, Rubicon model with Rock-Trac (241OR transfer case), locking differentials (front and rear), disconnecting front sway bar

📋 Manual Details

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Page Count:

Approximately 2000+ pages (typical for full factory manual)

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, component inspection, diagnosis

Engine Performance:

Fuel system, ignition system, emission control systems, cooling system, lubrication system, engine management (PCM)

Transmission Manual:

AX-5, AX-15, NV3550 overhaul, repair, troubleshooting

Transmission Automatic:

42RLE overhaul, repair, troubleshooting

Drivetrain:

Transfer case (NV231, NV241OR), Dana 30 front axle, Dana 35 rear axle, Dana 44 rear axle (Rubicon models), driveshafts, universal joints

Suspension:

Front and rear suspension components, springs, shocks, control arms, track bars, bushings, alignment specifications

Steering:

Steering gear, power steering pump, steering column, tie rods, drag links, steering stabilizer

Brakes:

Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic system, bleeding procedures

Electrical System:

Battery, charging system, starting system, lighting, instrument cluster, power windows, locks, mirrors, horns, wipers

Body And Frame:

Frame inspection, body panel removal/installation, doors, hood, tailgate, convertible top, interior trim, seats, bumpers

HVAC:

Heating, ventilation, air conditioning system diagnosis and repair, refrigerant handling

Diagnostics:

OBD-II diagnostics, trouble codes (DTCs), diagnostic procedures, wiring diagrams, connector pinouts

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, tune-ups, lubrication

Repair:

Component removal, installation, adjustment, replacement, and overhaul

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, common problems and solutions

Specifications:

Torque specifications, clearances, fluid capacities, electrical values, diagnostic data

Depth Level:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Detail Level:

Step-by-step instructions, exploded views, diagrams, wiring schematics, diagnostic charts

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

Fully searchable text content

Print Quality:

High-resolution for clear visibility of diagrams and text

Printable:

Printable pages

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

4.0L Inline 6 Cylinder (OHV)

Engine Displacement:

3952 cc (241 cubic inches)

Bore X Stroke:

3.87 x 3.57 inches (98.3 x 90.5 mm)

Compression Ratio:

8.8:1

Fuel Type:

Unleaded Gasoline

Horsepower Net:

190 hp @ 4,600 rpm

Torque Net:

235 lb-ft @ 3,200 rpm

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Recommended Fuel Octane:

87 Octane Minimum

Cooling System Type:

Pressurized, Liquid-Cooled

Oil Type Specification:

API SG or SH, SAE 10W-30

Oil Capacity With Filter:

5.7 quarts (5.4 liters)

🔧 Transmission

Transmission Type Standard:

6-speed Manual Transmission (NV3550)

Transmission Type Optional:

4-speed Automatic Transmission (42RLE)

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant (MS-9224) or equivalent, SAE 75W-85 GL-4

Automatic Transmission Fluid:

Mopar ATF+4 (MS-9602) or equivalent

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Overall Length:

151.3 inches (3843 mm)

Overall Width:

66.5 inches (1689 mm)

Overall Height:

71.2 inches (1808 mm) (with soft top)

Ground Clearance:

10.1 inches (257 mm)

Curb Weight:

3,500 - 3,800 lbs (1588 - 1724 kg) (approx. depending on configuration)

Gross Vehicle Weight Rating Gvwr:

4,750 - 5,100 lbs (2155 - 2313 kg)

🛡️ Safety Features

NHTSA Rollover Resistance:

4/5 Star (Higher center of gravity due to off-road design)

Anti Lock Braking System:

Standard on all models (4-wheel disc brakes with ABS)

Airbags:

Driver and front passenger airbags

Seat Belts:

Three-point front seat belts, lap belts in rear (depending on configuration)

💡 Technology Features

Audio System:

Factory AM/FM/CD player with optional premium sound system, Sirius Satellite Radio readiness

Navigation:

Not available from the factory in 2004

Cruise Control:

Available on most models

Auxiliary Input:

Not standard, aftermarket solutions common

🔧 Maintenance

Oil And Filter Change:

Every 3,000 - 6,000 miles or 6 months (refer to manual for specific usage conditions)

Air Filter Replacement:

Every 15,000 - 30,000 miles (inspect more frequently for off-road use)

Engine Coolant Flush:

Every 30,000 - 60,000 miles or 2-5 years (depending on coolant type)

Spark Plug Replacement:

Approximately 100,000 miles (for platinum or iridium plugs)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 (MS-9602) or Mopar Power Steering Fluid

Common Wear Items:

Clutch wear (manual transmission), rear main seal leaks, exhaust manifold cracks, suspension bushings, wheel bearings, track bar wear.

Electrical Quirks:

Intermittent issues with the instrument cluster, body control module (BCM), and power accessories can occur, often related to ground points or connectors.

Rust Prone Areas:

Frame rails, rocker panels, floor pans, and the area around the fuel filler neck can be susceptible to rust, especially in areas with road salt.

📚 Vehicle History

Brand Origin:

Willys-Overland CJ series, tracing roots back to WWII military vehicles

Jeep Wrangler Tj Introduction:

Introduced in 1997 as a successor to the YJ Wrangler, featuring a return to round headlights and coil-spring suspension.

Tj Generation Major Updates:

Significant chassis and suspension redesign compared to YJ, improved interior comfort, introduction of the 4.0L inline-6 as the primary engine.

Production Start Year:

1996 (for 1997 model year)

Production End Year Tj:

2006

Manufacturing Location:

Toledo Complex, Toledo, Ohio, USA

🏆 Awards & Recognition

Popular Mechanics Car Of The Year:

Jeep Wrangler received this award multiple times in its history, highlighting its enduring appeal and capability.

Four Wheeler Magazine 4X4 Of The Year:

The TJ Wrangler platform, particularly the Rubicon variant, has frequently been recognized for its off-road prowess.

Consumer Reports Reliability:

Varied; often cited for strong mechanicals but potential for minor electrical and body-related issues.