2005-Wrangler TJ Workshop Service Repair Manual

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Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Year: 2005 Codes Chassis Code: TJ Introduction Market Position Market Segment: The Jeep Wrangler TJ is a highly iconic and recognized...

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Description

Basic Information
Identification
Make:	Jeep
Model:	Wrangler
Generation:	TJ
Year:	2005
Codes
Chassis Code:	TJ

Introduction
Market Position
Market Segment:	The Jeep Wrangler TJ is a highly iconic and recognized off-road focused vehicle. In 2005, it competed in the compact SUV/off-road vehicle segment, but with a distinct identity and purpose that set it apart from more car-based SUVs. Its primary appeal was to outdoor enthusiasts, off-roaders, and those seeking a rugged, open-air driving experience.
Competitive Analysis
Key Competitors 2005:	While direct competitors were few, it was often cross-shopped with vehicles like the Toyota FJ Cruiser (though launched later), Nissan Xterra, and Hummer H3 (also launched later). However, the TJ's unique leaf-spring rear suspension and classic design gave it a different appeal.
Key Features
Unique Selling Points:	['Legendary off-road capability', 'Convertible design (removable doors, windshield, top)', 'Solid front axle (on most TJ models, though coil springs were introduced)', 'Robust body-on-frame construction', 'Short wheelbase for maneuverability']

Manual Details
Coverage Areas
Systems Covered:	['Introduction', 'Lubrication & Maintenance', 'Suspension', 'Differential & Driveline', 'Brakes', 'Clutch', 'Cooling System', 'Audio/Video Systems', 'Chime/Buzzer Systems', 'Electronic Control Modules (ECMs)', 'Engine', 'Exhaust System', 'Frame and Body', 'Fuel System', 'Ignition System', 'HVAC (Heating, Ventilation, and Air Conditioning)', 'Instrument Cluster', 'Lighting', 'Manual Transmission', 'Occupant Protection (Airbags, Seatbelts)', 'Power Steering', 'Power Windows & Locks', 'Rear Axle', 'Seats', 'Service and Repair', 'Speed Control (Cruise Control)', 'Starting System', 'Steering', 'Tires and Wheels', 'Towing', 'Transfer Case', 'Upholstery', 'Vehicle Identification Number (VIN) Information', 'Wiper/Washer Systems']
Page Count
Estimated Page Count:	Approximately 1500-2000 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:	Workshop Service Repair Manual
Language
Language:	English
Format
Format:	Likely PDF or digital format, with potential for printed versions.

Manual Coverage
Systems Covered
Detailed Systems:	Engine mechanical, engine control systems (PCM/ECM diagnostics), fuel injection, ignition timing, cooling system (radiator, thermostat, water pump, hoses), lubrication system (oil pump, oil filter, oil pan), exhaust manifold, catalytic converter, emissions control systems, manual transmission (clutch operation, gearbox repair), transfer case operation and maintenance, front and rear axle assembly (differential gears, axle shafts, bearings), driveline components (universal joints, CV joints), braking system (hydraulic lines, master cylinder, wheel cylinders/calipers, brake pads/shoes, parking brake), suspension system (springs, shock absorbers, control arms, bushings, ball joints, sway bars), steering system (steering gear, tie rods, steering column), power steering system (pump, hoses, rack/gear), electrical system (battery, alternator, starter, wiring harnesses, fuses, relays, lighting circuits), body and chassis (frame, body panels, doors, glass, interior trim), HVAC system (compressor, condenser, evaporator, blower motor, heater core), safety systems (airbags, seatbelt pre-tensioners), audio/video components, and diagnostic procedures.
Procedures Included
Repair Procedures:	['Engine disassembly, inspection, and reassembly', 'Transmission removal, disassembly, and reassembly', 'Differential overhaul and adjustment', 'Brake caliper replacement, rotor resurfacing/replacement, brake line bleeding', 'Suspension component replacement (shocks, springs, control arms)', 'Steering gear box or rack and pinion replacement', 'Driveline component repair (U-joint replacement, CV boot replacement)', 'Cooling system flushing and component replacement', 'Fuel pump and injector service', 'Electrical troubleshooting and component replacement (alternator, starter, sensors)', 'Body panel alignment and repair', 'Interior trim removal and installation', 'HVAC system diagnostics and component replacement', 'Wheel alignment procedures and specifications', 'Torque specifications for all critical fasteners']
Technical Depth
Depth Of Information:	Comprehensive. Covers everything from routine maintenance and fluid changes to complex component overhauls and diagnostic troubleshooting. Includes detailed step-by-step repair instructions, exploded views, wiring diagrams, diagnostic trouble codes (DTCs) and their probable causes, and technical service bulletins (TSBs) related to common issues. Designed for professional technicians and experienced DIY enthusiasts.

Manual Specifications
File Format
Digital Format Details:	If digital (PDF), expect searchable text, high-resolution diagrams, and hyperlinked sections for easy navigation. Printable pages ensure flexibility for workshop use.
Print Quality
Print Quality Description:	Typically features clear, crisp printing of text and diagrams. Professional binding for durability in a workshop environment.
Binding Type
Binding Type:	If printed: Perfect binding or spiral binding for ease of use and lay-flat capability.
Paper Type
Paper Type:	If printed: Durable, often coated paper to resist grease and dirt in a workshop setting.

Engine Specifications
Primary Engine
Engine Code And Type:	4.0L Inline-6 (PowerTech) - OHV 12-valve
Engine Displacement:	3952 cc (241 cubic inches)
Bore X Stroke:	3.878 in x 3.578 in (98.4 mm x 90.9 mm)
Compression Ratio:	8.8:1
Performance
Horsepower Rating:	190 hp @ 4600 rpm
Torque Rating:	235 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery Type:	Multi-point Fuel Injection (MPI)
Recommended Fuel:	87 Octane Unleaded Gasoline
Engine Oil
Oil Type And Viscosity:	API SJ or SL, SAE 5W-30
Oil Capacity With Filter:	5.0 US quarts (4.7 Liters)
Cooling System
Coolant Type:	Chrysler OAT (Organic Acid Technology) or equivalent, typically orange
Coolant Capacity:	10.7 US quarts (10.1 Liters)

Transmission
Standard
Transmission Type:	NV3550 5-speed manual transmission
Optional
Transmission Type Optional:	42RLE 4-speed automatic transmission
Features
Manual Transmission Gear Ratios:	1st: 4.01:1, 2nd: 2.25:1, 3rd: 1.39:1, 4th: 1.00:1, 5th: 0.77:1, Reverse: 3.51:1
Automatic Transmission Gear Ratios:	1st: 2.80:1, 2nd: 1.53:1, 3rd: 1.00:1, 4th: 0.71:1, Reverse: 2.00:1
Fluid Specifications
Manual Transmission Fluid Type:	Mopar Manual Transmission Lubricant (MS-9224) or equivalent, typically GL-3/GL-4, SAE 75W-90
Automatic Transmission Fluid Type:	Mopar ATF+4 (MS-9602) or equivalent
Fluid Capacities
Manual Transmission Fluid Capacity:	2.3 US quarts (2.2 Liters)
Automatic Transmission Fluid Capacity:	7.0 US quarts (6.6 Liters)

Dimensions
Exterior
Wheelbase:	93.4 inches (2372 mm)
Overall Length:	151.4 inches (3845 mm)
Overall Width:	66.5 inches (1689 mm)
Overall Height:	71.5 inches (1816 mm) (soft top)
Ground Clearance:	10.5 inches (267 mm)
Weights
Curb Weight:	Approximately 3,100 - 3,500 lbs (1406 - 1588 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:	4,600 lbs (2087 kg)
Towing Capacity:	2,000 lbs (907 kg)
Payload Capacity:	Approximately 1,100 lbs (499 kg)

Safety Features
Ratings
NHTSA Rollover Rating:	4 out of 5 stars
Active Features
Braking System:	Front ventilated disc, rear solid disc (standard on most models)
Anti Lock Braking System ABS:	Standard
Traction Control:	Available, especially on higher trims or specific packages
Passive Features
Airbags:	Driver and front passenger airbags
Seatbelts:	3-point front seatbelts, 2-point rear seatbelts
Rollover Protection:	Integral roll cage structure

Technology Features
Infotainment
Audio System Options:	Factory AM/FM/CD player with 4-6 speakers. Optional Infinity speaker upgrade available. Cassette player optional on some models.
Driver Assistance
Cruise Control:	Standard on most trims.
Power Features:	Power windows and door locks were optional on lower trims and standard on higher trims (e.g., Rubicon, Sahara).
Connectivity
Connectivity Options:	Limited by modern standards. No Bluetooth or USB ports from the factory. Analog connections for auxiliary devices were uncommon.

Maintenance
Service Intervals
Oil And Filter Change:	Every 3,000-5,000 miles or 6 months, whichever comes first (depending on driving conditions and oil used)
Engine Air Filter Replacement:	Every 15,000-30,000 miles or as needed based on inspection
Transmission Fluid Change Manual:	Every 30,000-50,000 miles or as recommended by manufacturer
Transmission Fluid Change Automatic:	Every 30,000 miles or as recommended by manufacturer (ATF+4 is generally more robust)
Transfer Case Fluid Change:	Every 30,000-50,000 miles
Differential Fluid Change:	Every 30,000-50,000 miles
Coolant Flush And Replacement:	Every 30,000-50,000 miles or 3-5 years
Spark Plug Replacement:	100,000 miles (long-life platinum or iridium)
Fluid Specifications
Power Steering Fluid:	Mopar Power Steering Fluid (MS-5901) or equivalent
Brake Fluid:	DOT 3
Known Issues
Common Problems Tj:	['Cracked cylinder heads on early 4.0L engines (less common by 2005, but still a possibility)', 'Oil filter housing leaks', 'Radiator leaks and potential for overheating', 'Leaky rear main seal', 'Worn out leaf springs or control arm bushings', 'Death Wobble (front-end shimmy, often related to steering/suspension components)', 'Frame rust (especially in certain climates)', 'Door seal leaks and water intrusion', 'Alternator failures', 'Clutch wear (manual transmission)']

Vehicle History
Brand Heritage
Jeep Legacy:	Jeep has a storied history dating back to World War II, known for its rugged, go-anywhere capability and military origins.
Model Evolution
Tj Generation Timeline:	The TJ generation of the Jeep Wrangler was introduced for the 1997 model year and ran through 2006. It marked a significant departure from its YJ predecessor by returning to the round headlights and, crucially, adopting coil springs for all four wheels, providing a vastly improved ride and articulation compared to the leaf-sprung YJ. The 2005 model year saw minor updates and refinements.
Production
Manufacturing Location:	Toledo, Ohio, USA

Awards & Recognition
Recognitions
Off Road Accolades:	Consistently recognized as one of the most capable off-road vehicles available, often winning awards in dedicated off-road publications and events.
Ratings
Consumer Satisfaction:	While not always top-tier in refined comfort or on-road manners, the TJ Wrangler typically scored well for its capability, durability, and the passion of its owner base.