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2005 Jeep Wrangler TJ Workshop Service Repair Manual

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The 2005 Jeep Wrangler TJ represents a pinnacle of off-road engineering, building upon a rich heritage of rugged capability and iconic design. This compact SUV is renowned for its exceptional...
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2005 Jeep Wrangler TJ Workshop Service Repair Manual
The 2005 Jeep Wrangler TJ represents a pinnacle of off-road engineering, building upon a rich heritage of rugged capability and iconic design. This compact SUV is renowned for its exceptional off-road prowess, characterized by solid front and rear axles, robust transfer case options, and impressive ground clearance. Its classic Jeep styling, featuring the distinctive seven-slot grille and removable doors and top, offers a unique open-air driving experience. Engineered for adventure, the Wrangler TJ is powered by a reliable 4.0L Inline 6-cylinder engine, delivering 190 horsepower and 235 lb-ft of torque, paired with either a 6-speed manual or a 4-speed automatic transmission. Its enduring appeal lies in its blend of go-anywhere performance and a distinctive, utilitarian aesthetic. This comprehensive Workshop Service Repair Manual provides in-depth guidance for all mechanical and electrical systems, bodywork, and specifications pertinent to the 2005 Jeep Wrangler TJ. It covers essential maintenance procedures, including scheduled service intervals and fluid specifications, alongside detailed diagnostic and troubleshooting charts for common issues. Repair procedures are thoroughly explained, covering everything from basic component replacement to complex system overhauls, supported by wiring diagrams and technical specifications. This manual serves as an indispensable resource for owners, technicians, and mechanics, ensuring proper maintenance, efficient diagnosis, and accurate repair of the vehicle.
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
2005
Platform:
TJ
Codes
Chassis Code:
TJ
👋 Introduction
Market Position
Segment:
Compact SUV/Off-Road Vehicle
Usp:
Renowned off-road capability, iconic design, open-air driving experience, robust drivetrain.
Competitive Analysis
Competitors:
Toyota 4Runner, Nissan Xterra, Suzuki Vitara, Land Rover Defender (in certain markets).
Key Features
Off Road Features:
Solid front and rear axles, Command-Trac NV231 or optional Selec-Trac NV242 transfer case, skid plates, high ground clearance.
Design:
Classic Jeep seven-slot grille, round headlights, removable doors and top, short wheelbase.
📋 Manual Details
Coverage Areas
Primary Coverage:
All mechanical and electrical systems, bodywork, and specifications for the 2005 Jeep Wrangler TJ.
Secondary Coverage:
Diagnosis, troubleshooting, repair procedures, component identification, and wiring diagrams.
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4.0L I6), transmission (manual and automatic), transfer case, driveline, exhaust system, cooling system, fuel system.
Chassis:
Suspension (front and rear solid axles, coil springs, control arms, shocks), steering system, braking system (ABS optional), wheels and tires.
Electrical:
12V battery system, charging system (alternator), starting system, ignition system, lighting, instruments, HVAC controls, power accessories (windows, locks), body control module (BCM), diagnostics (OBD-II).
Body And Frame:
Frame construction, body panels, doors, hood, windshield, soft top/hard top, interior trim, bumpers.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid, transfer case fluid, differential fluid), filter replacements, lubrication.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, component testing procedures, wiring diagram interpretation.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including disassembly, inspection, repair, and reassembly.
Diagnostics:
Engine performance diagnostics, electrical system diagnostics, HVAC diagnostics, ABS diagnostics.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed torque specifications and alignment procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (text-searchable)
Print Quality
Printability:
High-resolution, printable pages.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
ERH (4.0L I6)
Displacement:
3952 cc (241.1 cubic inches)
Configuration:
Inline 6-Cylinder, Overhead Valve (OHV)
Performance
Horsepower:
190 hp @ 4,600 rpm
Torque:
235 lb-ft @ 3,200 rpm
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Maintenance
Oil Capacity With Filter:
6.0 US quarts (5.7 Liters)
Recommended Oil Viscosity:
SAE 10W-30 (API SJ or higher)
🔧 Transmission
Standard
Transmission Type Std:
NSG370 6-Speed Manual
Optional
Transmission Type Opt:
42RLE 4-Speed Automatic
Features
Transfer Case Std:
NV231 Command-Trac (Part-time 2WD/4WD)
Transfer Case Opt:
NV242 Selec-Trac (Full-time 4WD optional on some models)
Maintenance
Manual Transmission Fluid Spec:
MS-9224 or equivalent (NV3550/NSG370)
Automatic Transmission Fluid Spec:
ATF+4 (MS-9602)
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
151.3 inches (3843 mm)
Width:
66.5 inches (1689 mm)
Height:
70.8 inches (1798 mm) (soft top)
Ground Clearance:
10.2 inches (259 mm)
Weights
Curb Weight Est:
3,153 - 3,333 lbs (1430 - 1512 kg)
Towing Capacity Est:
2,000 lbs (907 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3 Stars
Active Features
ABS:
Optional Anti-lock Braking System (ABS)
Traction Control:
Not standard
Passive Features
Airbags:
Driver and front passenger airbags
Seat Belts:
Three-point front seat belts, two-point rear seat belts
💡 Technology Features
Infotainment
Audio System Std:
AM/FM stereo with CD player, 4 speakers
Infotainment Options:
Optional Infinity sound system, SiriusXM satellite radio capability.
Driver Assistance
Cruise Control:
Available
Climate Control:
Manual HVAC system
Connectivity
Aux Input:
Not standard, optional on some models
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first.
Tire Rotation:
Every 7,500 miles or 6 months.
Engine Coolant Flush:
Every 30,000 miles or 2 years.
Fluid Specifications
Brake Fluid:
DOT 3
Power Steering Fluid:
Chrysler MS-5946R or equivalent
Transfer Case Fluid:
ATF+4 (for NV242), or Mopar Manual Transmission Lubricant (for NV231, check manual)
Differential Fluid Front Rear:
API GL-5, SAE 80W-90 (non-limited slip), SAE 75W-140 (limited slip)
Known Issues
Common Problems:
Oil filter housing leaks, exhaust manifold cracks, clutch issues (manual), radiator leaks, death wobble (suspension related), NP231 transfer case chain stretch.
Parts Information
Oil Filter Part Number Est:
Mopar 04541188 (or equivalent like Wix 57356, Fram PH3550)
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Iconic off-road vehicle lineage dating back to WWII Willys MB.
Model Evolution
Tj Generation:
Second generation of the modern Jeep Wrangler, introduced in 1997. Known for returning to coil springs and front coil buckets.
Tj Updates 2005:
Minor updates for 2005 often included interior trim refinements and potentially minor suspension tuning.
Production
Production Period Tj:
1997-2006
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently ranked as one of the most capable off-road vehicles by automotive publications.
Ratings
Consumer Reports Reliability:
Varies by year, often mid-pack for reliability compared to mainstream SUVs.
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