🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation Code: TJ Model Year: 2004 👋 Introduction Market Position Target Audience: Jeep Wrangler TJ owners, mechanics, and restoration specialists. Value Proposition: Essential tool for accurate part identification and sourcing, saving time and preventing incorrect part purchases. Competitive Analysis Advantage Over Generic Catalogs: OEM specific, ensuring correct fitment and application for the 2004 Wrangler TJ. Key Features Illustrated Diagrams: Exploded views provide clear visual context for part relationships. Part Number Listing: Critical for ordering the exact OEM replacement parts. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive parts catalog for Jeep Wrangler TJ 2004 models. Component Coverage: Engine, drivetrain, chassis, suspension, steering, brakes, electrical system, body, interior, accessories. Page Count Estimated Pages: Variable, typically 400-700 pages for a comprehensive TJ parts catalog. Manual Type Type: OEM Replacement Parts Manual / Parts Catalog. Language Language: English Format Format: Illustrated, Exploded Parts Diagrams with Part Numbers. 📖 Manual Coverage Systems Covered Engine Assembly: Detailed diagrams and part numbers for engine block, cylinder head, valvetrain, oil pump, water pump, intake, exhaust, and accessories. Transmission Drivetrain: Diagrams for manual and automatic transmissions, transfer case, propeller shafts, differentials, axles, and hub assemblies. Suspension Steering: Parts for front and rear suspension, control arms, springs, shock absorbers, steering gear, tie rods, drag links, and sway bars. Brake System: Components for front and rear brakes, including calipers, rotors, pads, lines, master cylinder, and parking brake. Electrical System: Diagrams for wiring harnesses, battery, alternator, starter, fuse box, lighting, ignition, and various sensors. Body Exterior: Components for body panels, doors, fenders, hood, grille, bumpers, windshield, and soft top/hard top hardware. Interior Trim: Parts for dashboard, seats, carpets, door panels, center console, steering wheel, and climate control components. Cooling Heating Exhaust: Radiator, fan, hoses, heater core, exhaust manifolds, catalytic converter, muffler, and pipes. Procedures Included Disassembly Assembly Reference: Facilitates disassembly and reassembly by providing clear visual references of part placement. Part Identification: Enables accurate identification of specific replacement parts via part numbers. Technical Depth Depth: Detailed component level breakdown, suitable for both DIY enthusiasts and professional mechanics for parts sourcing and identification. 📊 Manual Specifications File Format Digital Format Potential: Likely available as PDF, printable format. Print Quality Illustration Quality: High quality, clear exploded diagrams. Binding Type Physical Binding: Typically softcover or comb binding for printed versions. Paper Type Paper Quality: Durable paper stock, suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Common: Likely covers the 4.0L inline-6 (AMC 242) and potentially the 2.4L 4-cylinder (EDZ) for 2004 models. Displacement 4.0L: 3957 cc (242 cubic inches) Horsepower 4.0L: Approximately 190 hp @ 4600 rpm Torque 4.0L: Approximately 235 lb-ft @ 3200 rpm Displacement 2.4L: 2429 cc (148 cubic inches) Horsepower 2.4L: Approximately 150 hp @ 5600 rpm Torque 2.4L: Approximately 170 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-port fuel injection (MPI). Fuel Type: Unleaded gasoline, 87 octane recommended. 🔧 Transmission Standard Transmission Transmission Type Standard: 6-speed manual transmission (NV3550). Optional Transmission Transmission Type Optional: 4-speed automatic transmission (42RLE). Features Transfer Case: Command-Trac NV241 GII part-time manual transfer case or optional Selec-Trac full-time 4WD system. 📐 Dimensions Exterior Dimensions Typical Wheelbase: 93.4 inches (2372 mm) Length: 160.5 inches (4077 mm) Width Body: 66.7 inches (1694 mm) Height To Top Of Hardtop: 73.2 inches (1859 mm) Weights Curb Weight Approx: 3500-3800 lbs (1588-1724 kg), depending on configuration. Cargo Dimensions Cargo Volume Behind Front Seats: Approximately 46.4 cu ft (1314 liters) with rear seat folded. Cargo Volume Behind Rear Seats: Approximately 17.2 cu ft (487 liters) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-star rating for the 2004 model year (typical for TJ). NHTSA Front Impact Passenger: 5-star rating for the 2004 model year (typical for TJ). Active Features ABS: Anti-lock Braking System (ABS) often standard or optional depending on trim. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Three-point seat belts with pretensioners. 💡 Technology Features Infotainment Audio System Options: Factory radio with AM/FM, CD player, and optional premium sound system. Aftermarket upgrades common. Driver Assistance ABS Availability: Available on some models, particularly higher trims or later production years. Connectivity Basic Connectivity: Limited connectivity; primarily focused on audio playback. No integrated Bluetooth or USB in standard factory units. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-7,500 miles (5,000-12,000 km) or every 6 months, depending on oil type and driving conditions. Consult Owner's Manual for specifics. Tire Rotation Interval: Every 5,000-7,500 miles (8,000-12,000 km). Transmission Fluid Change Auto: Every 30,000-60,000 miles (48,000-97,000 km), check for severe duty. Transmission Fluid Change Manual: Typically every 30,000-60,000 miles (48,000-97,000 km). Fluid Specifications Engine Oil Spec 4.0L: SAE 10W-30 API Service SG or higher. Engine Oil Capacity 4.0L: 5 US quarts (4.7 Liters) with filter. Coolant Type: Ethylene Glycol based, Mopar OAT (Organic Additive Technology) or equivalent. Automatic Transmission Fluid Type: Chrysler...
Facilitates disassembly and reassembly by providing clear visual references of part placement.
Part Identification:
Enables accurate identification of specific replacement parts via part numbers.
Technical Depth
Depth:
Detailed component level breakdown, suitable for both DIY enthusiasts and professional mechanics for parts sourcing and identification.
📊 Manual Specifications
File Format
Digital Format Potential:
Likely available as PDF, printable format.
Print Quality
Illustration Quality:
High quality, clear exploded diagrams.
Binding Type
Physical Binding:
Typically softcover or comb binding for printed versions.
Paper Type
Paper Quality:
Durable paper stock, suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
Likely covers the 4.0L inline-6 (AMC 242) and potentially the 2.4L 4-cylinder (EDZ) for 2004 models.
Displacement 4.0L:
3957 cc (242 cubic inches)
Horsepower 4.0L:
Approximately 190 hp @ 4600 rpm
Torque 4.0L:
Approximately 235 lb-ft @ 3200 rpm
Displacement 2.4L:
2429 cc (148 cubic inches)
Horsepower 2.4L:
Approximately 150 hp @ 5600 rpm
Torque 2.4L:
Approximately 170 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-port fuel injection (MPI).
Fuel Type:
Unleaded gasoline, 87 octane recommended.
🔧 Transmission
Standard Transmission
Transmission Type Standard:
6-speed manual transmission (NV3550).
Optional Transmission
Transmission Type Optional:
4-speed automatic transmission (42RLE).
Features
Transfer Case:
Command-Trac NV241 GII part-time manual transfer case or optional Selec-Trac full-time 4WD system.
📐 Dimensions
Exterior Dimensions Typical
Wheelbase:
93.4 inches (2372 mm)
Length:
160.5 inches (4077 mm)
Width Body:
66.7 inches (1694 mm)
Height To Top Of Hardtop:
73.2 inches (1859 mm)
Weights
Curb Weight Approx:
3500-3800 lbs (1588-1724 kg), depending on configuration.
Cargo Dimensions
Cargo Volume Behind Front Seats:
Approximately 46.4 cu ft (1314 liters) with rear seat folded.
Cargo Volume Behind Rear Seats:
Approximately 17.2 cu ft (487 liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-star rating for the 2004 model year (typical for TJ).
NHTSA Front Impact Passenger:
5-star rating for the 2004 model year (typical for TJ).
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or optional depending on trim.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System Options:
Factory radio with AM/FM, CD player, and optional premium sound system. Aftermarket upgrades common.
Driver Assistance
ABS Availability:
Available on some models, particularly higher trims or later production years.
Connectivity
Basic Connectivity:
Limited connectivity; primarily focused on audio playback. No integrated Bluetooth or USB in standard factory units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles (5,000-12,000 km) or every 6 months, depending on oil type and driving conditions. Consult Owner's Manual for specifics.
Tire Rotation Interval:
Every 5,000-7,500 miles (8,000-12,000 km).
Transmission Fluid Change Auto:
Every 30,000-60,000 miles (48,000-97,000 km), check for severe duty.
Transmission Fluid Change Manual:
Typically every 30,000-60,000 miles (48,000-97,000 km).
Fluid Specifications
Engine Oil Spec 4.0L:
SAE 10W-30 API Service SG or higher.
Engine Oil Capacity 4.0L:
5 US quarts (4.7 Liters) with filter.
Coolant Type:
Ethylene Glycol based, Mopar OAT (Organic Additive Technology) or equivalent.
Automatic Transmission Fluid Type:
Chrysler ATF+4 (MS-9602).
Manual Transmission Fluid Type:
Mopar Manual Transmission Lubricant (MS-9224) or equivalent 75W-90 synthetic.
Transfer Case Fluid Type:
Mopar NT-700 (MS-9224) or equivalent 75W-90 synthetic.
Differential Fluid Type:
Hypoid gear oil SAE 80W-90 API GL-5. Use friction modifier for LSD if equipped.
Known Issues
Common Tj Issues:
Cracked exhaust manifolds (4.0L), rear main seal leaks, rust on unibody frame, heater control valve failure, sway bar disconnect issues (Rubicon), interior water leaks.
Manual Utility For Issues:
Provides correct part numbers for replacement of commonly failing components.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a storied history dating back to World War II, synonymous with off-road capability and ruggedness.
Model Evolution
Tj Introduction:
The TJ Wrangler was introduced for the 1997 model year, marking a significant redesign from its YJ predecessor, notably returning to round headlights and coil spring suspension.
Tj Updates For 2004:
The 2004 model year saw minor updates, often including revised interior trim and features.
Production
Production Era:
1997-2006
Manufacturing Location:
Toledo, Ohio, USA.
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
Jeep Wrangler TJ consistently recognized for its off-road prowess and capability, a benchmark in its class.
Ratings
Consumer Satisfaction:
Generally well-regarded by owners for its durability and iconic status, though reliability can vary with maintenance.
Certifications
Oem Certification:
This manual represents OEM specifications, ensuring authenticity and proper fit for original parts.
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