🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Model Year:

1996

Chassis Code:

TJ

👋 Introduction

Vehicle Class:

Compact SUV / Off-road vehicle

Target Audience:

Off-road enthusiasts, Jeep owners, DIY mechanics, professional technicians

Competitors 1996:

Toyota Land Cruiser, Nissan Pathfinder, Ford Bronco, Chevrolet Blazer

Jeep Philosophy:

Renowned for its off-road capability, ruggedness, and open-air driving experience.

Quality Assurance:

Superior quality manual, avoiding incomplete and inferior alternatives.

📋 Manual Details

Primary Coverage:

Comprehensive Service and Repair

Specific Systems Covered:

Engine, Transmission, Drivetrain, Brakes, Suspension, Steering, Electrical, HVAC, Body, Emissions

Estimated Page Count:

1000+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, component testing, diagnostics, timing, lubrication, cooling

Engine Performance:

Fuel injection, ignition system, emission control systems, turbocharging (if applicable)

Transmission Manual:

Removal, disassembly, reassembly, adjustment, diagnostics

Transmission Automatic:

Removal, disassembly, reassembly, hydraulic system, electronic controls, diagnostics

Drivetrain 4Wd:

Transfer case operation, front and rear axle assemblies, drive shafts, universal joints, differentials

Brakes:

Disc brake systems (front and rear), ABS diagnostics and repair, parking brake

Suspension:

Front and rear suspension components, coil springs, shock absorbers, bushings, alignment

Steering:

Power steering system, steering column, steering gear, tie rods

Electrical System:

Battery, starting system, charging system, lighting, instrumentation, wiring diagrams, fuse and relay locations

HVAC:

Air conditioning system, heating system, ventilation, component testing, refrigerant handling

Body And Chassis:

Frame repair, body panel replacement, doors, hood, tailgate, interior trim, glass, bumpers

Emissions Control:

Catalytic converter, EGR system, evaporative emission control system, OBD-II diagnostics

Maintenance Schedules:

Routine maintenance, fluid changes, filter replacements, inspections

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common problem identification

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Diagnostic Testing:

Procedures for testing sensors, actuators, electrical circuits, and mechanical components

Rebuild Procedures:

Detailed instructions for complete engine, transmission, and axle overhauls

Depth:

Comprehensive: from basic maintenance to complete component rebuilds and advanced diagnostics

Diagnostics Level:

Advanced diagnostic procedures, including use of scan tools and interpretation of fault codes

Repair Detail:

Detailed exploded views, torque specifications, special tool requirements

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for on-site use

Image Resolution:

High-resolution images and diagrams

Binding:

N/A (Digital)

Paper:

N/A (Digital)

Completeness Statement:

Complete manual with no missing pages, covering all aspects of the vehicle's service and repair.

⚙️ Engine Specifications

Engine Code:

2.5L Inline-4 (AMC 150) / 4.0L Inline-6 (AMC 242)

Displacement 2 5L:

2.5 Liters (150 cu. in.)

Horsepower 2 5L:

123 hp @ 4,600 rpm

Torque 2 5L:

137 lb-ft @ 3,200 rpm

Displacement 4 0L:

4.0 Liters (242 cu. in.)

Horsepower 4 0L:

181 hp @ 4,600 rpm

Torque 4 0L:

220 lb-ft @ 3,200 rpm

Compression Ratio 2 5L:

8.8:1

Compression Ratio 4 0L:

8.75:1

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum (4.0L), Cast Iron (2.5L)

Ignition System:

Distributorless Ignition System (DIS)

🔧 Transmission

Standard Transmission Type:

5-Speed Manual (AX-5 for 2.5L, NV3550 for 4.0L)

Optional Transmission Type:

4-Speed Automatic (42RLE)

Transfer Case:

Command-Trac NV231 (Part-time, 2WD/4WD High/Low)

Clutch Type:

Hydraulic Dry Single Plate

📐 Dimensions

Wheelbase:

93.4 inches

Length:

151.3 inches

Width:

66.5 inches

Height:

70.1 inches

Passenger Capacity:

4

Cargo Volume Behind Rear Seat:

28.7 cu. ft.

Cargo Volume With Rear Seat Folded:

56.5 cu. ft.

Curb Weight 2 5L:

Approx. 3,200 lbs

Curb Weight 4 0L:

Approx. 3,400 lbs

Standard Tire Size:

P215/75R15

Optional Tire Size:

P225/75R16, LT235/75R15

Wheel Bolt Pattern:

5 x 4.5 inches (114.3 mm)

🛡️ Safety Features

NHTSA Rollover Resistance:

3/5 stars (demonstrates inherent tendency for SUVs)

ABS:

Available Anti-lock Braking System (ABS) on rear wheels

Airbags:

Driver and passenger front airbags

Seatbelts:

Three-point front seat belts, two-point rear seat belts

Frame Type:

Body-on-frame construction

💡 Technology Features

Audio System:

AM/FM stereo, optional CD player, speaker configurations varied by trim

Cruise Control:

Available

Connectivity Features:

Minimal by modern standards; focus on functional robustness rather than digital integration.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months (depending on driving conditions)

Transmission Fluid Change Interval Manual:

Every 30,000-60,000 miles

Transmission Fluid Change Interval Auto:

Every 30,000-60,000 miles

Coolant Flush Interval:

Every 24,000-30,000 miles or 24 months

Spark Plug Replacement:

Approx. 100,000 miles (depending on spark plug type)

Engine Oil Spec:

API SJ or SL, SAE 10W-30 or 5W-30 (depending on climate), 4.0L: 5 US quarts with filter, 2.5L: 4 US quarts with filter

Transmission Fluid Manual:

AX-5: ATF+4 (Mopar Part # 05013457AA), NV3550: SAE 75W-90 synthetic gear oil

Transmission Fluid Automatic:

ATF+4 (Mopar Part # 05013457AA)

Transfer Case Fluid:

ATF+4 (Mopar Part # 05013457AA)

Differential Fluid:

GL-5 80W-90 (with friction modifier for limited-slip differentials, if equipped)

Coolant Type:

Mopar Antifreeze/Coolant (HOAT) or equivalent, 50/50 mix with distilled water

Common Issues Engine 4 0L:

Cylinder head crack (especially early models), oil filter adapter seal leaks, camshaft and lifter noise

Common Issues Engine 2 5L:

Oil leaks, intake manifold gasket leaks

Common Issues Transmission:

AX-5 synchro wear, NV3550 input shaft bearing failure

Common Issues Suspension Steering:

Worn ball joints, tie rod ends, control arm bushings, steering box looseness

Common Issues Electrical:

Alternator failures, starter motor issues, grounds corrosion

Common Issues Body:

Door hinge rust, tailgate rust, body mount corrosion

📚 Vehicle History

Jeep Legacy:

Direct descendant of the original Willys MB military Jeep from WWII, symbolizing ruggedness and off-road capability.

Tj Introduction:

Introduced for the 1997 model year, the TJ Wrangler replaced the YJ. This manual incorrectly states 1996, but the TJ platform began with 1997. Assuming this is a typo and refers to the TJ generation.

Tj Design Philosophy:

Return to round headlights (a callback to CJ models), coil spring suspension for improved ride and articulation, and a more modern interior.

Manufacturing Location:

Toledo, Ohio, USA

Tj Production Span:

1997 - 2006

🏆 Awards & Recognition

Offroad Magazine Awards:

Consistently recognized for off-road prowess and capability by automotive publications.

Consumer Reports Reliability:

Mixed; often praised for durability in off-road use but can have average to below-average reliability for certain components.