🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

JK (early production phase)

Product Name:

Jeep WRANGLER Service Repair Workshop Manual 2004-2006

Model Years Covered:

2004, 2005, 2006

👋 Introduction

Positioning:

The Jeep Wrangler (TJ generation, early facelift) for 2004-2006 occupies a unique niche as a highly capable off-road vehicle with a significant enthusiast following. This manual caters to owners and technicians who maintain and repair this iconic model.

Comparison:

While competitors like the Toyota FJ Cruiser emerged later, the TJ Wrangler of this era was largely in a class of its own for its dedicated off-road focus and iconic design. Maintenance and repair would have been primarily handled by Jeep dealerships and independent mechanics specializing in off-road vehicles.

Manual Value:

Provides detailed, manufacturer-approved procedures essential for accurate and efficient maintenance and repair, ensuring the longevity and optimal performance of the Jeep Wrangler.

Vehicle Significance:

Represents a period of evolution for the Wrangler, bridging the gap between the classic CJ and the later JK, known for its robust build and off-road prowess.

📋 Manual Details

Comprehensive Coverage:

All models and all repairs A-Z

Specificity:

Vehicle/model specific, not generic

Target Audience:

Dealership technicians, advanced DIY enthusiasts

Estimated Page Count:

Varies by specific manual edition, typically 1500+ pages for complete workshop manuals covering multiple engines/transmissions.

Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECM/PCM), transmission (manual and automatic), transfer case, driveline (axles, driveshafts).

Chassis:

Suspension (front and rear), steering system, braking system (ABS, disc/drum configurations), wheels and tires, frame and chassis components.

Electrical:

Battery, charging system, starting system, lighting (headlights, taillights, interior), instrument cluster, power windows, power locks, mirrors, wiper/washer system, HVAC electrical controls, audio systems, body control modules (BCM), wiring diagrams, diagnostic connector (OBD-II).

Body:

Exterior body panels, interior trim, doors, hoods, liftgates, glass, bumpers, seats, safety restraints (airbags, seatbelts), body sealing.

Maintenance:

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

Diagnostics:

Troubleshooting procedures for all systems, diagnostic trouble codes (DTCs), symptom-based diagnosis, testing procedures for sensors and actuators.

Repair:

Component removal and installation, assembly and disassembly of major systems, adjustment procedures, overhaul procedures.

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters.

Depth:

Comprehensive: Covers routine maintenance, in-depth diagnostics, component-level repairs, and complete system overhauls.

Detail Level:

Includes step-by-step instructions with accompanying diagrams, illustrations, and exploded views.

📊 Manual Specifications

Type:

PDF

Searchability:

Likely text-searchable for efficient information retrieval.

Quality:

High-resolution diagrams and text, suitable for printing specific sections.

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code And Type:

4.0L Inline 6-Cylinder (PowerTech), OHV, 12-valve

Engine Code And Type Alternative:

2.4L 4-Cylinder (PowerTech - less common, primarily for export or specific trims)

Horsepower 4.0L:

Approx. 190 hp @ 4600 rpm

Torque 4.0L:

Approx. 235 lb-ft @ 3200 rpm

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

ECU Type:

Engine Control Module (ECM) / Powertrain Control Module (PCM)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically Mopar 05010855AA or equivalent.

Oil Type:

SAE 10W-30 API Certified Synthetic Blend or Conventional Motor Oil.

Oil Capacity 4.0L:

5.7 US quarts (5.4 liters) with filter change.

🔧 Transmission

Transmission Type:

NV3550 5-speed Manual Transmission

Transmission Type:

42RLE 4-speed Automatic Transmission

Transfer Case:

NV241G-II 2-speed part-time, Command-Trac transfer case (standard)

Fluid Type:

Mopar Manual Transmission Lubricant (MS-9224) or equivalent, typically a GL-3 or GL-4 rated gear oil.

Fluid Type:

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

📐 Dimensions

Wheelbase 2-Door:

96.7 inches (2456 mm)

Wheelbase 4-Door (Unlimited):

N/A for this model year range (Unlimited model introduced later)

Length 2-Door:

Approx. 160.0 inches (4064 mm)

Width 2-Door:

Approx. 66.7 inches (1694 mm)

Height 2-Door:

Approx. 70.5 inches (1791 mm)

Curb Weight 2-Door:

Approx. 3,500 - 4,000 lbs (1588 - 1814 kg), varies by configuration.

Towing Capacity:

Up to 2,000 lbs (907 kg) for manual transmission, 3,500 lbs (1588 kg) for automatic transmission (with proper equipment).

🛡️ Safety Features

NHTSA Front Impact Driver:

Likely 4 out of 5 stars (for 2005 model year, specific data for 2004/2006 may vary slightly).

NHTSA Front Impact Passenger:

Likely 4 out of 5 stars (for 2005 model year).

IIHS Side Impact:

Good (for 2001-2007 TJ generation, as structure remained largely consistent).

ABS:

Standard Anti-lock Braking System (ABS) on front disc brakes, optional on rear drums.

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point front seat belts, lap belts for rear passengers (depending on seat configuration).

Rollover Protection:

Integral sport bar (roll cage) for occupant protection.

💡 Technology Features

Audio System:

Basic AM/FM stereo with CD player, optional Infinity speaker systems. Availability of MP3 playback and auxiliary input varies by trim and option package.

Cruise Control:

Available on most models.

Traction Control:

Available as an option on some models, often linked with ABS.

OBD Ii Port:

Standard OBD-II diagnostic port located under the dashboard for engine and emission system diagnostics.

HVAC:

Manual or optional air conditioning and heating systems. Cabin filtration was not standard on all models.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plug Replacement 4.0L:

Champion Copper Plus (RC12LYC) or equivalent, recommended replacement every 30,000 - 60,000 miles depending on driving conditions and spark plug type used.

Transmission Fluid Change Automatic:

Inspect every 30,000 miles (48,000 km), change fluid and filter every 60,000 - 100,000 miles (96,000 - 160,000 km) or as recommended by severe service. Always use ATF+4.

Differential Fluid Change:

Inspect every 30,000 miles (48,000 km), change every 60,000 miles (96,000 km), especially if used for off-roading or towing. Use appropriate gear oil (e.g., 75W-90 GL-5 for front/rear differentials).

Brake Fluid:

DOT 3 or DOT 4, check owner's manual for specific recommendation. Use Mopar Brake Fluid or equivalent.

Power Steering Fluid:

Chrysler Power Steering Fluid (MS-5901) or equivalent, typically a Dexron III/Mercon compatible ATF.

Common Problem 1:

Radiator and coolant leaks (especially the radiator itself and heater core). Proper cooling system maintenance is crucial.

Common Problem 2:

Front axle universal joint (U-joint) wear, particularly if subjected to heavy off-road use. Regular greasing is recommended.

Common Problem 3:

Frame rust, especially in areas with road salt. Regular inspection and undercoating are advised.

Common Problem 4:

Clutch pedal assembly wear (manual transmission) leading to poor clutch engagement. Clutch fluid leaks can also occur.

Common Problem 5:

PCM (Powertrain Control Module) failures, often related to moisture ingress or electrical issues. The manual will detail diagnostic procedures.

📚 Vehicle History

Jeep Legacy:

The Jeep brand has a storied history dating back to World War II, renowned for its ruggedness and off-road capability. The Wrangler is the direct descendant of the original Willys Jeep.

Tj Generation:

The 2004-2006 models represent the latter half of the TJ generation (1997-2006), which introduced significant improvements over its YJ predecessor, including coil spring suspension for a more comfortable ride and better articulation.

Updates 2004-2006:

Minor updates during this period included potential feature packaging changes and refinements to existing systems. The powertrain remained largely the same.

Manufacturing Location:

Toledo, Ohio, USA

Production Years:

TJ generation: 1997-2006

🏆 Awards & Recognition

Off Road Accolades:

The Jeep Wrangler (TJ) consistently received praise for its off-road prowess from various automotive publications and enthusiast groups throughout its production run.

Consumer Reports Reliability:

Reliability ratings varied for the TJ generation, often cited as average to below average in consumer surveys, particularly for early models. However, its robust mechanicals and simplicity contributed to its longevity for those who maintained it well.

Safety Certifications:

Meets all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for its model years.