🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Model Code:

TJ

Year:

2005

Platform Code:

TJ

👋 Introduction

Target Audience:

Jeep Wrangler TJ owners, DIY mechanics, automotive repair shops, enthusiasts seeking in-depth knowledge of the 2005 Jeep Wrangler.

Manual Advantage:

Provides original manufacturer data, ensuring accuracy and completeness, superior to generic repair guides. Covers all factory specifications and procedures.

Key Selling Points:

Original factory content, comprehensive coverage, detailed wiring diagrams, searchable and bookmarked PDF, covers major mechanical and electrical systems.

📋 Manual Details

Coverage:

Body, Chassis, Electrical, Engine, Drivetrain, Suspension, Steering, Brakes, HVAC, Interior Components, Wiring Diagrams

Page Count:

Estimated 1500+ pages (typical for a complete factory service manual of this era)

Manual Type:

Original Factory Service & Repair Manual

Language:

English

Format:

Digital PDF

📖 Manual Coverage

Engine Systems:

4.0L (Code: ERH), 2.4L (Code: ED1) Engine (Troubleshooting, Diagnostics, Repair, Rebuild, Component Identification, Torque Specifications, Maintenance)

Transmission Systems:

NV3550 5-Speed Manual Transmission, NV241OR Command-Trac Transfer Case (Operation, Diagnostics, Repair, Fluid Specifications, Capacities)

Chassis Systems:

Dana 30 Front Axle, Dana 35c Rear Axle (with optional Trac-Lok), Suspension (Coil Springs, Shock Absorbers, Control Arms), Steering System (Power Steering Pump, Gearbox, Tie Rods), Brake System (Front Disc, Rear Drum/Disc, ABS components)

Electrical Systems:

Comprehensive Wiring Diagrams for all circuits, Lighting System, Ignition System, Charging System, Starting System, Instrumentation, Power Accessories, Audio System, Security System, Diagnostic Trouble Codes (DTCs) and Powertrain Control Module (PCM) functions

Maintenance Procedures:

Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Belt Replacement, Air Filter Replacement, Fuel Filter Replacement, Tire Rotation, Lubrication Points

Repair Procedures:

Engine tune-up, cylinder head removal/installation, piston and connecting rod service, crankshaft service, camshaft service, cooling system repair, fuel injection system repair, exhaust system repair, clutch replacement, transmission overhaul, axle differential service, suspension component replacement, steering component replacement, brake caliper/wheel cylinder overhaul, ABS system diagnosis and repair, starter motor replacement, alternator replacement, battery service, interior trim removal/installation, body panel alignment and repair

Diagnostic Procedures:

Systematic troubleshooting guides for common drivability issues, electrical faults, and mechanical failures. Includes symptom-based diagnostics and guided component testing.

Depth:

Comprehensive diagnostic procedures, detailed repair instructions with step-by-step guidance, torque specifications for all fasteners, clearances and adjustments, exploded views of component assemblies, special tool recommendations, and electrical schematics.

📊 Manual Specifications

File Format:

PDF

Searchability:

Fully searchable text

Bookmarking:

Extensive bookmarking for easy navigation

Compatibility:

Compatible with Windows, Linux, and Mac operating systems

Print Quality:

High-resolution for clear diagrams and text

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Options:

4.0L Inline 6-Cylinder (242 ci), 2.4L DOHC 4-Cylinder (147 ci - less common)

4.0L Horsepower:

190 hp @ 4600 rpm (approx.)

4.0L Torque:

235 lb-ft @ 3200 rpm (approx.)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 5-Year/100,000 Mile Formula (or equivalent meeting Chrysler MS-9769)

Spark Plugs:

NGK ZFR6AP-11GS (Platinum or Iridium recommended) - consult manual for exact part numbers and gap

Engine Oil Viscosity:

SAE 5W-30 (for 4.0L engine), SAE 10W-30 (for 2.4L engine)

Engine Oil Capacity 4.0L:

5 US quarts (4.7 Liters) with filter change

Engine Oil Specification:

API Certified, ILSAC GF-4 or higher, meeting Chrysler MS-6395

🔧 Transmission

Manual Transmission:

NV3550 5-Speed Manual Transmission

Automatic Transmission:

42RLE 4-Speed Automatic Transmission

Transfer Case:

NV241OR 'Command-Trac' (Part-Time, 2WD High, 4WD High, Neutral, 4WD Low)

Manual Transmission Fluid Type:

Mopar Manual Transmission Lubricant (or equivalent meeting Chrysler MS-9224) - typically a synthetic 75W-90 gear oil

Automatic Transmission Fluid Type:

Mopar ATF+4 (MS-9602) - Automatic Transmission Fluid

Nv3550 Capacity:

2.1 US quarts (1.9 Liters)

42Rle Capacity:

6.5 US quarts (6.2 Liters) - initial fill

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

150.3 inches (3818 mm)

Width:

66.5 inches (1689 mm)

Height:

70.0 inches (1778 mm)

Curb Weight:

Approximately 3,100-3,500 lbs (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approximately 4,300 lbs

Cargo Volume Behind Front Seats:

Approx. 44.5 cu ft

Cargo Volume Behind Rear Seats:

Approx. 15.1 cu ft

🛡️ Safety Features

NHTSA Rollover Resistance:

3-star rating (for 2005 models)

ABS:

Available on 4-wheel disc brake models (standard on some higher trims).

Airbags:

Driver and Passenger Frontal Airbags

Seatbelts:

3-point front seat belts, 2-point rear lap belts

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player, optional Infinity speaker system.

Traction Control:

Optional on some models, typically a brake-lock differential system.

Cruise Control:

Available option on most trims.

Keyless Entry:

Available option on higher trims.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe driving conditions may require more frequent changes.

Tire Rotation Interval:

Every 5,000 miles (8,000 km)

Transmission Fluid Change Manual:

Inspect every 15,000 miles (24,000 km). Replace as needed or every 30,000-50,000 miles (48,000-80,000 km) depending on usage and fluid condition. Consult manual for detailed recommendations.

Transmission Fluid Change Automatic:

Inspect every 15,000 miles (24,000 km). Replace every 30,000-50,000 miles (48,000-80,000 km) under normal conditions, more frequently for severe duty.

Coolant Flush Interval:

Every 100,000 miles (160,000 km) or 5 years for the original fill (Mopar OAT), then every 50,000 miles (80,000 km) or 5 years thereafter.

Brake Fluid Type:

DOT 3 (or DOT 4, if specified for updated systems)

Power Steering Fluid Type:

Mopar Power Steering Fluid (or equivalent meeting Chrysler MS-5901) - typically ATF+4 compatible.

Common Wear Items:

Clutch wear (manual transmission), ball joints, tie rod ends, sway bar links, oil filter housing gasket leaks (4.0L), exhaust manifold cracks (4.0L), radiator and heater core failures.

Electrical Issues:

Corrosion on grounds and connectors, intermittent wiper function, gauge cluster issues, power window failures (if equipped).

Axle Issues:

Bearing wear in Dana axles, especially with oversized tires or heavy off-road use.

📚 Vehicle History

Jeep Legacy:

Jeep has a long-standing heritage in producing rugged, off-road capable vehicles, dating back to WWII.

Tj Generation Introduction:

The TJ generation of the Jeep Wrangler was introduced for the 1997 model year, replacing the YJ. Key improvements included coil spring suspension on all four corners, a significant upgrade from the YJ's leaf springs.

Tj Updates 2005:

For 2005, the TJ received minor updates, including revised interior trim and available options. The core mechanicals, including the robust 4.0L engine and Dana axles, remained largely the same.

Manufacturing Location:

Toledo, Ohio, USA

Production Years Tj:

1997-2006

🏆 Awards & Recognition

Off Road Capability Acclaim:

The Jeep Wrangler (TJ) is consistently recognized as a benchmark for off-road capability and has been a favorite among off-road enthusiasts for its robust design and aftermarket support.

Consumer Satisfaction:

While specific awards for the 2005 model may vary, the TJ generation generally received positive consumer feedback for its iconic styling, durability, and off-road prowess, though often noted for on-road comfort trade-offs.