🏷️ Basic Information Identification Make: Jeep Model: Wrangler Model Code: TJ Generation Generation: 2nd Generation (TJ) Codes Production Years: 1997-2006 Manual Coverage Years: 2004, 2005, 2006 👋 Introduction Market Position Vehicle Segment: Compact SUV, Off-Road Vehicle Target Audience: Off-road enthusiasts, adventure seekers, owners prioritizing ruggedness and capability. Competitive Analysis Key Competitors: Toyota 4Runner, Ford Bronco (older generations), Suzuki Samurai. Key Features Off Road Capability: Iconic solid front and rear axles, available locking differentials, robust four-wheel-drive systems, high ground clearance. Versatility: Removable doors, top, and windshield; convertible for open-air driving experiences. Durability: Known for its rugged construction and ability to withstand demanding off-road conditions. 📋 Manual Details Coverage Areas Major Systems Covered: Engine, Transmission, Drivetrain, Brakes, Steering, Suspension, Electrical System, HVAC, Body, Interior Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component testing, torque specifications, timing belt/chain service, piston and ring installation, cylinder head reconditioning. Fuel System: Fuel pump testing, injector service, fuel pressure regulator diagnosis, evaporative emission control (EVAP) system troubleshooting. Cooling System: Radiator service, water pump replacement, thermostat testing, coolant specifications, fan clutch diagnosis. Exhaust System: Muffler and catalytic converter replacement, exhaust manifold repair, oxygen sensor testing and replacement. Transmission Manual: NV3550 (AX-15 successor) overhaul, clutch service, shift linkage adjustment, component diagnostics. Transmission Automatic: 42RLE (optional) overhaul, torque converter replacement, valve body diagnosis, shift solenoid testing, fluid specifications. Drivetrain 4X4: NV241OR (242OR) transfer case service, Dana 30 front axle, Dana 35c rear axle overhaul, axle spline counts, differential fluid specifications, U-joint replacement, driveshaft service. Brakes: Front disc brake service (caliper, rotor, pad replacement), rear drum brake service (shoes, drum, wheel cylinder replacement), ABS system diagnostics, brake fluid specifications, bleeding procedures. Steering: Power steering system diagnosis, pump replacement, steering gear (steering box) adjustment and overhaul, tie rod end replacement, alignment specifications. Suspension: Front and rear suspension component replacement (shocks, springs, control arms, bushings), sway bar link replacement, lift kit installation considerations. Electrical System: Wiring diagrams for all circuits, fuse box locations, relay identification, battery charging system diagnosis, starter motor service, alternator testing. Lighting System: Headlight, taillight, turn signal, and interior lighting bulb replacement and troubleshooting, connector diagnostics. Instrument Panel: Gauge cluster removal and installation, warning light diagnosis, odometer troubleshooting. HVAC System: Air conditioning system service (refrigerant recharge, leak detection, compressor replacement), heater core replacement, blower motor testing, climate control system diagnosis. Body Exterior: Door panel removal, fender replacement, hood adjustment, bumper fascia repair, hardtop and soft top service, tailgate and door hinge repair. Body Interior: Seat removal and installation, dashboard disassembly, carpet replacement, sound deadening installation, trim panel repair. Procedures Included Routine Maintenance: Oil change, filter replacement, tire rotation, brake inspection, fluid level checks, spark plug replacement, air filter replacement. Troubleshooting Diagnostics: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, OBD-II diagnostic trouble codes (DTCs) explained. Component Replacement: Step-by-step instructions for replacing major and minor components across all systems. Engine Rebuild: Complete engine overhaul instructions, including disassembly, cleaning, inspection, machining specifications, and reassembly. Transmission Rebuild: Detailed procedures for rebuilding both manual and automatic transmissions. Electrical Diagnostics: Troubleshooting electrical circuits using wiring diagrams, multimeter usage, testing relays and switches, power and ground checks. Body Repair: Panel alignment, rust repair techniques, door and window glass replacement, soft top and hardtop maintenance. Special Tools: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth Level: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Print Quality Printability: High-quality, printable pages Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement Liter: 4.0 Engine Name: Jeep 4.0L Inline-6 (Power Tech) Engine Code: ERH (for 2004-2006 models, though minor variations exist) Performance Horsepower Hp: 190 Torque Lb Ft: 235 Fuel System Fuel Delivery: Electronic Fuel Injection (Sequential MPI) Recommended Fuel: 87 Octane Unleaded Gasoline 🔧 Transmission Standard Transmission Type: 6-Speed Manual Manual Transmission Model: NV3550 Optional Transmission Type: 4-Speed Automatic Automatic Transmission Model: 42RLE Features Transfer Case: 2-speed NV242OR (Command-Trac) with 4-Hi Part-Time, 4-Lo Part-Time 📐 Dimensions Exterior Wheelbase In: 93.4 Length In: 156.7 Width In: 66.5 Height In: 73.4 Ground Clearance In: 10.1 Weights Curb Weight Lbs: 3600-3900 (approx.) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 3 Stars (due to inherent design and purpose) Active Features ABS: Standard on all models for these years. Passive Features Airbags: Driver and passenger front airbags. Body Construction: Body-on-frame construction, roll cage integrated into the cabin structure. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional Infinity sound system with amplifier and subwoofer. Basic functionality. Driver Assistance Driver Assistance Features: Limited to ABS. No advanced electronic...