2004 Jeep Wrangler Tj Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Chassis Code: TJ Codes Engine Code: Various (commonly 4.0L I6) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Chassis Code:

Codes

Engine Code:

Various (commonly 4.0L I6)

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking reliable repair information

Competitive Analysis

Key Competitors 2004:

Toyota Tacoma, Nissan Xterra, Ford Explorer Sport Trac

Key Features

Vehicle Distinctiveness:

Iconic off-road capability, removable doors and top, solid front axle (pre-2007)

Manual Value Proposition:

Empowers owners to perform complex repairs and maintenance, saving on labor costs.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive factory service and repair

Page Count

Page Count Estimated:

1500+

Manual Type

Manual Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Repair:

Detailed diagnosis, repair, and overhaul procedures for all engine options

Transmission Repair:

Service and repair for manual and automatic transmissions

Drivetrain Repair:

Axles, differentials, transfer case (NV241OR/NV241GHD), driveshafts

Suspension Repair:

Front and rear suspension, shock absorbers, springs, control arms, linkages

Brake System Repair:

Front and rear brake assemblies, ABS diagnostics and repair

Steering System Repair:

Power steering system, steering gear, steering column

Electrical System Repair:

Battery, charging system, starting system, lighting, ignition, wiring diagrams

HVAC System Repair:

Heating, ventilation, and air conditioning system diagnosis and repair

Body And Chassis Repair:

Frame, body panels, doors, seats, interior trim, convertible top

Emissions Control System:

Diagnosis and repair of emissions components and systems

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides

Component Removal And Installation:

Step-by-step instructions for component R&I

Rebuilding Procedures:

Detailed procedures for engine, transmission, and axle rebuilding

Torque Specifications:

Critical torque values for fasteners across all systems

Wiring Diagrams:

Comprehensive electrical schematics with component identification

Technical Depth

Depth Level:

Factory-level detail, suitable for professional technicians and advanced DIYers

Diagnostic Procedures:

In-depth diagnostic strategies, including scan tool data interpretation

Special Tools:

Identification and usage instructions for specialized service tools

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval

Print Quality

Image Clarity:

High-resolution diagrams, illustrations, and photographs

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type Standard:

4.0L (242 cu in) Inline-6, Overhead Valve (OHV), Pushrod

Engine Displacement Liters:

Engine Configuration:

Inline-6

Bore X Stroke:

3.875 in x 3.414 in (98.4 mm x 86.7 mm)

Compression Ratio:

8.8:1

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Horsepower Net Hp:

190 hp @ 4600 rpm

Torque Net Lb-Ft:

235 lb-ft @ 3200 rpm

Ignition System:

Distributorless Ignition System (DIS)

Cooling System:

Pressurized, coolant-cooled

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity Gallons:

🔧 Transmission

Standard

Transmission Type Standard:

AX-5 5-speed manual transmission

Optional

Transmission Type Optional:

42RLE 4-speed automatic transmission

Features

Transfer Case:

NV241OR (4-Wheel Drive, Part-Time, 2-Speed)

Clutch Type:

Hydraulically actuated, single dry plate (manual)

📐 Dimensions

Exterior

Wheelbase Inches:

Overall Length Inches:

151.4

Overall Width Inches:

Overall Height Inches:

70.5 (with hardtop)

Ground Clearance Inches:

approx. 8.8

Approach Angle Degrees:

approx. 43.0

Departure Angle Degrees:

approx. 37.0

Breakover Angle Degrees:

approx. 25.0

Weights

Curb Weight Lbs:

3300-3500 (approx.)

Gross Vehicle Weight Rating Gvwr Lbs:

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Driver:

4 Stars

NHTSA Frontal Crash Passenger:

4 Stars

NHTSA Side Impact Front Driver:

5 Stars

NHTSA Side Impact Front Passenger:

5 Stars

Active Features

Standard Anti-lock Braking System (ABS) - 4-wheel disc brakes

Traction Control:

Optional

Passive Features

Airbags:

Driver and front passenger airbags

Rollover Protection:

Sport cage integrated into body structure

💡 Technology Features

Infotainment

Infotainment System:

Base AM/FM stereo with CD player; optional premium sound system

Speakers:

Standard 4 speakers; optional 6-speaker system

Driver Assistance

Driver Assistance Features:

Limited; primarily ABS

Connectivity

Connectivity Options:

Limited; often requires aftermarket upgrades for modern connectivity

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Engine Coolant Flush:

Every 30,000-50,000 miles or 2-3 years

Transmission Fluid Change Auto:

Every 30,000-60,000 miles

Transmission Fluid Change Manual:

Every 30,000-60,000 miles

Fluid Specifications

Engine Oil Type And Viscosity:

API certified SAE 10W-30 (preferred), SAE 5W-30 in extreme cold

Engine Oil Capacity Quarts:

5.0 (with filter)

Coolant Type:

Chrysler OAT (Orange) Antifreeze/Coolant, 50/50 mixture with distilled water

Automatic Transmission Fluid Type:

ATF+4 (MS-9602)

Manual Transmission Fluid Type:

MS-9224 (90W GL-3 or GL-4 for AX-5, 75W-90 GL-4 for NV3550/NVC-145, refer to manual for exact specs)

Power Steering Fluid Type:

ATF+4

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Item Clutch:

Clutch wear and failure in manual transmissions

Common Wear Item Suspension:

Wear in control arm bushings, track bar bushings, and ball joints due to off-road use.

Common Engine Issue Ticking:

"Ticking" noise from the 4.0L engine due to lifter noise, often exacerbated by oil type/level.

Common Electrical Issue Wiring:

Corrosion in electrical connectors, especially for exterior lighting and trailer wiring.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct descendant of WWII Willys MB, synonymous with off-road capability

Model Evolution

Tj Generation Period:

1997-2006

Tj Key Advancement:

Return to coil springs and the iconic round headlights, reintroduction of the solid front axle.

Production

Production Plant:

Toledo South Assembly Plant, Toledo, Ohio

🏆 Awards & Recognition

Recognitions

Off Road Magazine Awards:

Consistently ranked high in off-road capability reviews by automotive publications