Jeep Wrangler TJ Workshop Manual 2004

🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Year:

2004

Chassis Code:

TJ

👋 Introduction

Market Position:

Essential diagnostic and repair resource for Jeep Wrangler TJ owners and independent repair facilities, providing dealership-level information for the 2004 model year.

Competitive Analysis:

This is a Factory Service Manual (FSM), offering superior detail and accuracy compared to aftermarket generic repair guides. Its comprehensiveness makes it the gold standard for in-depth vehicle maintenance and repair.

Key Features:

Complete FSM, technician-level accuracy, detailed diagrams, extensive coverage of all vehicle systems, official Jeep documentation.

📋 Manual Details

Coverage Areas:

Comprehensive coverage for all service and repair procedures, including General Information, Maintenance, Engine Mechanical, Engine Lubrication & Cooling Systems, Engine Fuel & Emission Control System, Accelerator Control, Fuel and Exhaust Systems, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft & Differential Carrier, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Brake System, Steering System, Restraint System, Body and Trim, Heater, Air Conditioner, Electrical System, and more.

Electrical System Detail:

Covers lighting, ignition, charging system, power distribution, instrumentation, wipers, horn, and accessory circuits.

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Manual Use Case:

Designed for technicians and advanced DIYers, providing the necessary technical information for professional repair and maintenance.

Language:

English

Format:

PDF (within a RAR archive)

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Lubrication, Engine Cooling, Fuel System, Emission Control, Accelerator Control, Exhaust System, Clutch System, Manual Transmission, Automatic Transmission, Drivetrain (Propeller Shaft, Differential Carrier, Front Axle, Rear Axle), Suspension (Front & Rear), Brakes, Steering, Restraint Systems (Airbags), HVAC (Heater, Air Conditioner), Electrical System, Body & Trim.

Wiring Diagrams Coverage:

Detailed wiring diagrams included for the electrical system, covering all circuits, components, and their interconnections.

Chassis And Body Coverage:

Detailed information on body panel removal/installation, frame inspection, and interior trim components.

Procedures Included:

Maintenance, Service, Diagnosis, Repair, Troubleshooting, Wiring Diagrams, Component Removal/Installation, Adjustments, Specifications.

Diagnostic Procedures:

Step-by-step diagnostic procedures for identifying and resolving issues across all vehicle systems, including fault codes.

Suspension And Steering Repair:

Procedures for servicing front and rear suspension components, steering gear, and related systems, including alignment specifications.

Technical Depth:

Comprehensive; equivalent to dealership technician-level documentation, covering basic to advanced repair and diagnostic procedures.

Engine Rebuild Depth:

Complete engine disassembly, inspection, repair, and reassembly procedures.

Transmission Repair Depth:

In-depth repair procedures for both manual and automatic transmissions, including torque specifications and internal component details.

📊 Manual Specifications

File Format:

RAR archive containing PDF documents.

Print Quality:

High quality PDF, suitable for printing individual pages or sections.

Binding Type:

Digital Download (No physical binding)

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine:

4.0L Inline 6-Cylinder (242 ci) 'Power Tech' I6

Horsepower 2004 4.0L:

190 hp @ 4,600 rpm

Torque 2004 4.0L:

235 lb-ft @ 3,200 rpm

Fuel System Type:

Multi-point Fuel Injection (MPI)

Engine Code 4.0L:

ERH

Cooling System Type:

Pressurized, liquid-cooled

🔧 Transmission

Standard Transmission:

6-speed NV3550 Manual Transmission

Optional Transmission:

4-speed 42RLE Automatic Transmission

Transfer Case:

NV241OR 'Off-Road' Command-Trac (Standard)

Transfer Case Gear Ratios:

2.72:1 (low range)

📐 Dimensions

Wheelbase Tj:

93.4 inches

Length Tj:

160.0 inches

Width Tj:

66.5 inches

Height Tj:

70.1 inches

Curb Weight Tj 4.0L:

Approx. 3,310 - 3,460 lbs

🛡️ Safety Features

NHTSA Rollover Rating:

3-Star (for 2004 model year, varies slightly by configuration)

Active Safety Features:

Four-wheel disc brakes (standard on 2003+ models), ABS (optional/standard depending on trim)

Passive Safety Features:

Front airbags, Seat belts with pretensioners.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo with CD player, optional Infinity speaker system. Limited connectivity and advanced features compared to modern vehicles.

Driver Assistance Features:

None standard; ABS optional.

Connectivity Options:

Limited to aftermarket upgrades for Bluetooth or auxiliary inputs.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months (severe duty), 5,000 miles or 6 months (normal duty).

Engine Oil Type:

SAE 5W-30 API certified (meeting Chrysler MS-6395 spec recommended)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue (MS-9769)

Transmission Fluid Manual:

NS 235 (NV3550) or equivalent specification

Transmission Fluid Automatic:

ATF+4 (MS-9602) or equivalent

Differential Fluid Front Rear:

SAE 75W-90 GL-5 gear lubricant (with friction modifier for LSD)

Known Issues:

Radiator leaks, AC system issues, catalytic converter failure, clutch wear (manual), death wobble (suspension alignment/component wear), rust (frame, rocker panels, tub).

Standard Tire Size:

P215/75R15, P225/75R16, or P245/75R16 depending on trim and options.

Wheel Bolt Pattern:

5x4.5 inch (5x114.3 mm)

📚 Vehicle History

Brand Heritage:

Jeep, a division of Chrysler (now Stellantis), has a storied history dating back to World War II, renowned for its off-road capability and ruggedness.

Model Evolution:

The TJ Wrangler (1997-2006) marked a significant departure from its YJ predecessor by reintroducing coil springs for improved ride comfort and articulation. The 2004 model year saw minor updates and continued the TJ's legacy of iconic design and off-road prowess.

Production Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions:

Consistently ranked highly for off-road capability and Jeep's overall brand reputation. Praised for its go-anywhere, do-anything ethos.