Jeep WRANGLER TJ 4X4 (LHD) 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Model Year: 2005 Drive Type: 4X4 Steering Side: LHD (Left-Hand Drive) Codes Chassis Code: TJ 👋 Introduction Market Position Segment:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Model Year:

Drive Type:

Steering Side:

LHD (Left-Hand Drive)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking DIY repair and maintenance capabilities.

Competitive Analysis

Competitors 2005:

Ford Escape, Toyota RAV4, Honda CR-V, Land Rover Discovery (though direct competitors vary by capability focus).

Key Features Vehicle

Iconic Design:

Jeep's signature seven-slot grille, round headlights, and exposed hinges.

Off Road Capability:

Solid front and rear axles, optional limited-slip differentials, robust 4x4 system (Command-Trac).

Convertible Design:

Removable windshield, doors, and soft top/hard top options.

Manual Value Proposition

Empowerment:

Empowers owners to perform maintenance and repairs, saving costs and increasing vehicle understanding.

Comprehensiveness:

Covers all major systems, providing detailed steps and specifications.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair information for the 2005 Jeep Wrangler TJ 4x4 (LHD).

Page Count

Page Count:

Approximately 1500+ pages (typical for this era's service manuals).

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed diagnostic procedures, component testing, repair instructions for 4.0L I6 engine.

Transmission Service:

Repair and maintenance for NV3550 manual transmission and NV241OR transfer case.

Drivetrain Service:

Front and rear axle (Dana 30/35) disassembly, assembly, and repair.

Brake System Service:

Front disc and rear drum brake system diagnosis and repair, including ABS.

Suspension Steering:

Front and rear suspension, steering linkage, power steering system repair.

Electrical System Service:

Wiring diagrams, component testing, diagnostic procedures for charging, starting, lighting, and accessories.

Cooling Exhaust System:

Radiator, fan, water pump, exhaust manifold, and catalytic converter service.

Fuel System Service:

Fuel pump, injectors, pressure regulator, and evaporative emissions control system repair.

Climate Control HVAC:

Air conditioning system diagnosis and repair, heater core service.

Body And Chassis:

Body panel removal/installation, interior trim, seat repair, frame inspection.

Procedures Included

Preventative Maintenance:

Scheduled maintenance intervals, fluid checks and changes, filter replacements.

Troubleshooting Diagnostics:

Symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) interpretation, electrical system diagnostics.

Engine Repair:

Engine disassembly, component inspection, rebuilding procedures, timing chain replacement.

Transmission Rebuild:

Detailed steps for NV3550 manual transmission overhaul.

Brake Service Replacement:

Brake pad, rotor, caliper, and brake line replacement procedures.

Suspension Component Replacement:

Ball joint, tie rod end, shock absorber, and spring replacement.

Electrical Component Testing:

Testing alternators, starters, sensors, and actuators using multimeters and oscilloscopes.

Body Panel Alignment:

Door, hood, and fender alignment procedures.

Technical Depth

Depth Level:

Complete in-depth coverage, from basic maintenance to complex overhauls and diagnostics.

Diagnostic Tools:

Information relevant for use with OBD-II scan tools and specialized Chrysler diagnostic equipment.

Torque Specifications:

All essential torque specifications for critical fasteners are provided.

Clearances Tolerances:

Engine component clearances and assembly tolerances included.

Wiring Diagrams:

High-quality, detailed wiring diagrams for all electrical systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Printable:

Printable pages for on-the-go reference.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

ERH (4.0L)

Engine Type:

4.0L Inline 6-Cylinder (I6) Power Tech

Displacement:

242 cubic inches (3952 cc)

Performance

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Management

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug.

🔧 Transmission

Standard

Transmission Type:

NV3550 5-speed Manual Transmission

Optional

Transmission Type:

42RLE 4-speed Automatic Transmission

Features

Transfer Case:

NV241OR (Rock-Trac) - standard for Rubicon, Command-Trac for other models.

Transfer Case Gear Ratios:

2.72:1 (Command-Trac), 4.0:1 (Rock-Trac)

Fluid Specifications

Manual Transmission Fluid:

MS-9224 Manual Transmission Fluid (e.g., Mopar ATF+4 or equivalent)

Automatic Transmission Fluid:

ATF+4 (MS-9602)

Transfer Case Fluid:

NV241OR requires NP205 fluid (e.g., Dexron III/Mercon or equivalent)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

159.5 inches (4051 mm)

Width Body:

66.7 inches (1694 mm)

Height:

71.9 inches (1826 mm) (with hardtop)

Weights

Curb Weight Approx:

3500 - 4000 lbs (1588 - 1814 kg), depending on configuration.

Towing Capacity:

2000 lbs (907 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-star (subject to specific testing year, typically for light trucks of this era)

Active Features

Standard on 4WD models for 2005.

Passive Features

Airbags:

Driver and passenger front airbags.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player. Optional premium audio and Infinity speaker upgrades available.

Display:

Basic dashboard instrumentation, no integrated infotainment screen.

Driver Assistance

Cruise Control:

Available

Connectivity

Auxiliary Input:

Not standard, typically aftermarket additions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for exact recommendation).

Filter Replacement:

Engine oil filter: every oil change. Air filter: every 15,000 miles or annually. Fuel filter: typically every 30,000 miles (refer to manual).

Spark Plug Replacement:

Typically every 100,000 miles for platinum-tipped spark plugs.

Fluid Specifications

Engine Oil Spec:

API SJ or SL certified, SAE 10W-30 viscosity (check manual for severe/cold weather recommendations).

Coolant Spec:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a 50/50 mix with distilled water.

Brake Fluid Spec:

DOT 3

Power Steering Fluid:

Chrysler MS-5901 (Type 715)

Known Issues

Common Wear Items:

Clutch wear (manual transmission), front and rear driveshaft U-joints, sway bar links, track bar bushings.

Common Engine Concerns:

Cracked exhaust manifold (4.0L I6), oil filter adapter leaks, distributor O-ring leaks (earlier models, less common for '05).

Common Suspension Concerns:

Death wobble (requires proper diagnosis and tightening/replacement of steering/suspension components), worn control arm bushings.

Common Electrical Concerns:

Intermittent wiper issues, power window motor failures, clock spring failure (airbag system).

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's long history of producing capable off-road vehicles dating back to WWII.

Model Evolution

Tj Generation:

The TJ Wrangler (1997-2006) introduced coil springs, replacing the leaf springs of its predecessor (YJ), significantly improving ride comfort and articulation.

Significant Changes 2005:

Introduction of optional front and rear Dana 44 axles (Rubicon model), revised steering linkage, and standard ABS.

Production

Production Plant:

Toledo South Assembly Plant, Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized by off-road publications and enthusiasts for its class-leading capability.

Ratings

Consumer Reports Reliability:

Variable; often rated average for reliability in its class, with common wear-item issues noted.

Certifications

Emissions Compliance:

Meets all applicable US Federal emissions standards for the 2005 model year.