Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Model Code: JK (2007-2018), JL (2018-Present) Applicable Years: 2004 Onwards Manual Product Name: Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS Codes Chassis Codes Covered: TJ (up to 2006), JK, JL 👋 Introduction Market Position Segment: Compact/Mid-size SUV, Off-Road Vehicle Target Audience: Off-road enthusiasts, adventure seekers, Jeep owners requiring detailed repair information. Competitive Analysis Key Competitors: Toyota 4Runner, Ford Bronco, Land Rover Defender, Nissan Xterra. Key Features Off Road Capability: Renowned for its segment-leading off-road prowess with features like solid axles (older generations), 4x4 systems, and high ground clearance. Iconic Design: Distinctive seven-slot grille, round headlights, exposed hinges, and removable doors/roof contribute to its unique identity. 📋 Manual Details Coverage Areas Coverage Overview: Comprehensive workshop service and repair for all systems. Page Count Estimated Page Count: Extensive, typically 2000+ pages depending on variant and year. Manual Type Manual Type: Official Workshop Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system. Engine Performance: Fuel injection, ignition system, emissions control, turbocharging (if applicable). Transmission Manual: Clutch, gearbox assembly, internal components, linkages, fluid service. Transmission Automatic: Transmission assembly, torque converter, valve body, electronic controls, fluid service. Drivetrain: Transfer case (NVG/Rock-Trac/Command-Trac), front and rear drive shafts, differentials, axle assemblies (Dana 30, Dana 44), axle shafts, U-joints. Suspension: Front and rear suspension systems (coil springs, multi-link solid axle, independent front suspension for JL), shock absorbers, control arms, sway bars, bushings. Steering: Power steering system, steering gear, steering column, tie rods, drag links, steering stabilizer. Brakes: Front and rear brake systems (disc/disc), ABS, traction control, brake calipers, rotors, pads, lines, master cylinder, brake booster, parking brake. Electrical System: Battery, charging system (alternator), starting system, wiring diagrams, fuse box locations, relay assignments. Lighting: Headlights, taillights, turn signals, interior lighting, fog lights, wiring and bulb specifications. HVAC: Heating, ventilation, and air conditioning system (compressor, condenser, evaporator, blower motor, controls, refrigerant recharge). Body And Chassis: Body panels, doors, hood, fenders, bumpers, frame, VIN decoding, interior trim, convertible top mechanism. Restraints: Airbag system, seat belts, SRS module, diagnostic procedures. Infotainment And Electronics: Radio, navigation system, speakers, power windows, power locks, keyless entry, instrument cluster, trailer brake controller (optional). Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections. Diagnostic Troubleshooting: Step-by-step guides for identifying and resolving common and complex issues across all systems, including OBD-II codes. Repair And Rebuild: Detailed procedures for component removal, disassembly, inspection, repair, reassembly, and installation. Component Replacement: Instructions for replacing common wear items and major components. Specifications And Tolerances: Torque specifications, clearances, fluid capacities, and other critical technical data. Wiring Diagrams: Comprehensive, labeled wiring schematics for all electrical systems. Technical Depth Depth Level: Professional-grade, covering everything from basic adjustments to complete powertrain and chassis overhauls. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Searchability: Fully searchable text, allowing quick access to specific information. Image Resolution: High-resolution diagrams and illustrations suitable for printing. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 2004 2006 Tj: 4.0L (3952cc) Straight-6 "PowerTech" I6 OHV Engine 2007 2011 Jk: 3.8L (3778cc) V6 "Triton" OHV Engine 2012 2018 Jk: 3.6L (3604cc) V6 Pentastar VVT Engine 2018 Jl: 3.6L (3604cc) V6 Pentastar VVT, 2.0L (1995cc) Turbocharged I4 "Hurricane" Performance Hp 4.0L I6: Approx. 190 hp @ 4600 rpm Torque 4.0L I6: Approx. 235 lb-ft @ 3200 rpm Hp 3.8L V6: Approx. 202 hp @ 5200 rpm Torque 3.8L V6: Approx. 237 lb-ft @ 4000 rpm Hp 3.6L V6 Pentastar: Approx. 285 hp @ 6400 rpm Torque 3.6L V6 Pentastar: Approx. 260 lb-ft @ 4800 rpm Hp 2.0L Turbo I4: Approx. 270 hp @ 5250 rpm Torque 2.0L Turbo I4: Approx. 295 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) / Direct Injection (DI) for some Turbo models Fuel Type: Unleaded Gasoline (87 Octane minimum recommended) 🔧 Transmission Standard Transmission Tj: 5-Speed Manual (NV1500/NV3550) Transmission Jk Early: 6-Speed Manual (NSG370) Transmission Jk Late Jl: 6-Speed Manual (NSG370 / DTC NV3550) Optional Transmission Tj Auto: 4-Speed Automatic (42RLE) Transmission Jk Auto: 4-Speed Automatic (42RLE) until 2011, 5-Speed Automatic (W5A580/NAG1) 2012-2018, 8-Speed Automatic (850RE) JL Features Transfer Case Tj: Command-Trac NV231, Selec-Trac NV242 (optional) Transfer Case Jk: Command-Trac NV241, Rock-Trac NV241OR Transfer Case Jl: Selec-Trac Full-Time 4WD, Command-Trac Part-Time 4WD, Rock-Trac Full-Time 4WD 📐 Dimensions Exterior Wheelbase 2Dr: 95.4 inches (2423 mm) Wheelbase 4Dr Jk Jl: 116.0 inches (2946 mm) Overall Length 2Dr: Approx. 160-170 inches (4064-4318 mm) Overall Length 4Dr Jk Jl: Approx. 179-184 inches (4547-4674 mm) Cargo Cargo Volume Behind Rear Seat 2Dr: Approx. 13.4 cu ft (379 L) Cargo Volume Behind Rear Seat 4Dr Jk Jl: Approx....

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Tags: 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 Car Cars Jeep Misc WRANGLER

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Model Code:

JK (2007-2018), JL (2018-Present)

Applicable Years:

2004 Onwards

Manual Product Name:

Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS

Codes

Chassis Codes Covered:

TJ (up to 2006), JK, JL

👋 Introduction

Market Position

Segment:

Compact/Mid-size SUV, Off-Road Vehicle

Target Audience:

Off-road enthusiasts, adventure seekers, Jeep owners requiring detailed repair information.

Competitive Analysis

Key Competitors:

Toyota 4Runner, Ford Bronco, Land Rover Defender, Nissan Xterra.

Key Features

Off Road Capability:

Renowned for its segment-leading off-road prowess with features like solid axles (older generations), 4x4 systems, and high ground clearance.

Iconic Design:

Distinctive seven-slot grille, round headlights, exposed hinges, and removable doors/roof contribute to its unique identity.

📋 Manual Details

Coverage Areas

Coverage Overview:

Comprehensive workshop service and repair for all systems.

Page Count

Estimated Page Count:

Extensive, typically 2000+ pages depending on variant and year.

Manual Type

Manual Type:

Official Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system.

Engine Performance:

Fuel injection, ignition system, emissions control, turbocharging (if applicable).

Transmission Manual:

Clutch, gearbox assembly, internal components, linkages, fluid service.

Transmission Automatic:

Transmission assembly, torque converter, valve body, electronic controls, fluid service.

Drivetrain:

Transfer case (NVG/Rock-Trac/Command-Trac), front and rear drive shafts, differentials, axle assemblies (Dana 30, Dana 44), axle shafts, U-joints.

Suspension:

Front and rear suspension systems (coil springs, multi-link solid axle, independent front suspension for JL), shock absorbers, control arms, sway bars, bushings.

Steering:

Power steering system, steering gear, steering column, tie rods, drag links, steering stabilizer.

Brakes:

Front and rear brake systems (disc/disc), ABS, traction control, brake calipers, rotors, pads, lines, master cylinder, brake booster, parking brake.

Electrical System:

Battery, charging system (alternator), starting system, wiring diagrams, fuse box locations, relay assignments.

Lighting:

Headlights, taillights, turn signals, interior lighting, fog lights, wiring and bulb specifications.

HVAC:

Heating, ventilation, and air conditioning system (compressor, condenser, evaporator, blower motor, controls, refrigerant recharge).

Body And Chassis:

Body panels, doors, hood, fenders, bumpers, frame, VIN decoding, interior trim, convertible top mechanism.

Restraints:

Airbag system, seat belts, SRS module, diagnostic procedures.

Infotainment And Electronics:

Radio, navigation system, speakers, power windows, power locks, keyless entry, instrument cluster, trailer brake controller (optional).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections.

Diagnostic Troubleshooting:

Step-by-step guides for identifying and resolving common and complex issues across all systems, including OBD-II codes.

Repair And Rebuild:

Detailed procedures for component removal, disassembly, inspection, repair, reassembly, and installation.

Component Replacement:

Instructions for replacing common wear items and major components.

Specifications And Tolerances:

Torque specifications, clearances, fluid capacities, and other critical technical data.

Wiring Diagrams:

Comprehensive, labeled wiring schematics for all electrical systems.

Technical Depth

Depth Level:

Professional-grade, covering everything from basic adjustments to complete powertrain and chassis overhauls.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Searchability:

Fully searchable text, allowing quick access to specific information.

Image Resolution:

High-resolution diagrams and illustrations suitable for printing.

Binding Type

Binding Method:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 2004 2006 Tj:

4.0L (3952cc) Straight-6 "PowerTech" I6 OHV

Engine 2007 2011 Jk:

3.8L (3778cc) V6 "Triton" OHV

Engine 2012 2018 Jk:

3.6L (3604cc) V6 Pentastar VVT

Engine 2018 Jl:

3.6L (3604cc) V6 Pentastar VVT, 2.0L (1995cc) Turbocharged I4 "Hurricane"

Performance

Hp 4.0L I6:

Approx. 190 hp @ 4600 rpm

Torque 4.0L I6:

Approx. 235 lb-ft @ 3200 rpm

Hp 3.8L V6:

Approx. 202 hp @ 5200 rpm

Torque 3.8L V6:

Approx. 237 lb-ft @ 4000 rpm

Hp 3.6L V6 Pentastar:

Approx. 285 hp @ 6400 rpm

Torque 3.6L V6 Pentastar:

Approx. 260 lb-ft @ 4800 rpm

Hp 2.0L Turbo I4:

Approx. 270 hp @ 5250 rpm

Torque 2.0L Turbo I4:

Approx. 295 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) / Direct Injection (DI) for some Turbo models

Fuel Type:

Unleaded Gasoline (87 Octane minimum recommended)

🔧 Transmission

Standard

Transmission Tj:

5-Speed Manual (NV1500/NV3550)

Transmission Jk Early:

6-Speed Manual (NSG370)

Transmission Jk Late Jl:

6-Speed Manual (NSG370 / DTC NV3550)

Optional

Transmission Tj Auto:

4-Speed Automatic (42RLE)

Transmission Jk Auto:

4-Speed Automatic (42RLE) until 2011, 5-Speed Automatic (W5A580/NAG1) 2012-2018, 8-Speed Automatic (850RE) JL

Features

Transfer Case Tj:

Command-Trac NV231, Selec-Trac NV242 (optional)

Transfer Case Jk:

Command-Trac NV241, Rock-Trac NV241OR

Transfer Case Jl:

Selec-Trac Full-Time 4WD, Command-Trac Part-Time 4WD, Rock-Trac Full-Time 4WD

📐 Dimensions

Exterior

Wheelbase 2Dr:

95.4 inches (2423 mm)

Wheelbase 4Dr Jk Jl:

116.0 inches (2946 mm)

Overall Length 2Dr:

Approx. 160-170 inches (4064-4318 mm)

Overall Length 4Dr Jk Jl:

Approx. 179-184 inches (4547-4674 mm)

Cargo

Cargo Volume Behind Rear Seat 2Dr:

Approx. 13.4 cu ft (379 L)

Cargo Volume Behind Rear Seat 4Dr Jk Jl:

Approx. 31.5 cu ft (892 L)

Weights

Curb Weight 2Dr:

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

Curb Weight 4Dr Jk Jl:

Approx. 4,200 - 4,800 lbs (1905 - 2177 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

Varies by model year and configuration, often 3 or 4 stars for 2-door, 4 stars for 4-door (check specific year).

Active Features

Standard Anti-lock Braking System

Traction Control:

Standard Traction Control System (TCS)

Standard Electronic Stability Control (ESC) - introduced with JK generation

Hill Start Assist:

Available on later models (JK/JL)

Passive Features

Airbags:

Front airbags, side curtain airbags (available/standard depending on year/trim)

Seat Belts:

3-point seat belts with pretensioners

💡 Technology Features

Infotainment

Infotainment Systems Jk:

Uconnect systems with touchscreens (5", 6.5", 8.4" depending on year/trim), SiriusXM Satellite Radio, optional Navigation.

Infotainment Systems Jl:

Updated Uconnect systems (7", 8.4") with Apple CarPlay and Android Auto integration, SiriusXM Traffic and Travel Link.

Driver Assistance

Driver Assistance Features:

Available features include Blind-Spot Monitoring, Rear Cross-Path Detection, ParkView Rear Back-Up Camera, Forward Collision Warning (late models), Adaptive Cruise Control (late models).

Connectivity

Connectivity Options:

Bluetooth connectivity for hands-free calling and audio streaming, USB ports, available Wi-Fi Hotspot (JL).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specific engine).

Tire Rotation Interval:

Every 7,500 miles (12,000 km) or as part of oil change.

Transmission Fluid Change Manual:

Inspect every 30,000 miles (48,000 km); change as needed or every 60,000-100,000 miles (96,000-160,000 km) depending on usage.

Transmission Fluid Change Automatic:

Inspect every 30,000 miles (48,000 km); change typically every 60,000 miles (96,000 km) for normal use, or sooner for severe use (towing, off-roading).

Fluid Specifications

Engine Oil 4.0L I6:

SAE 10W-30 API SG or higher

Engine Oil 3.6L Pentastar:

SAE 0W-20 API SN or SP, MS-6395

Engine Oil 2.0L Turbo:

SAE 0W-20 API SP, MS-13375

Coolant:

Mopar OAT (Organic Additive Technology) HOAT antifreeze (MS-9769) or equivalent, 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 compatible brake fluid

Transfer Case Fluid:

Mopar NV241G Heavy Duty Lubricant or equivalent (check specific transfer case type)

Axle Differential Fluid:

SAE 75W-90 GL-5 gear oil. Friction modifier (Mopar LS additive or equivalent) required for limited-slip differentials.

Known Issues

Death Wobble Jk:

A common term for severe steering shimmy, often related to worn steering and suspension components (track bar, ball joints, tie rods, steering damper).

Oil Cooler Leaks Pentastar:

Potential for oil leaks from the oil filter housing and cooler assembly on Pentastar V6 engines.

Evaporator Case Leaks:

Water leaking into the cabin from the HVAC evaporator case, often due to clogged drain tubes.

Clutch Release Bearing Nsg370:

Some manual transmissions can experience noise from the clutch release bearing.

📚 Vehicle History

Brand Heritage

Jeep Origin:

Roots in military vehicles (Willys MB) during World War II, renowned for ruggedness and off-road capability.

Model Evolution

Tj Wrangler:

1997-2006. Introduced coil springs for a more comfortable ride, retained solid axles. Key features included the 4.0L inline-6 engine.

Jk Wrangler:

2007-2018. Major redesign. Introduced a unibody construction for the JK (though still considered body-on-frame by many), 4-door Unlimited model, modern amenities, and electronic stability/traction control. Engine options changed over its lifespan.

Jl Wrangler:

2018-Present. Further evolution. Lighter materials, more aerodynamic design, new engine options (2.0L Turbo, 3.0L EcoDiesel, 4xe Plug-in Hybrid), available independent front suspension (4xe models), and updated technology.

Production

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Awards:

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

Segment Awards:

Often cited as a leader in its class for capability and iconic status.