2004 Jeep Wrangler TJ Service Manual

Wiring diagrams, specifications, and repair sequences for Jeep Wrangler TJ. Documents procedures for suspension and steering systems.

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Jeep Models Covered & Key Technical Specifications

Models: Jeep Wrangler TJ
Sub-models / Variants: SE, X, Sport, Sahara, Rubicon, Wrangler 4X4 (LHD), Wrangler 4X4 (RHD)
Trade Names: Wrangler
Build Years: 2004
Serial Numbers: P = Toledo #2
Technical Data:

  • Engine displacement: 2.4L 4 cyl DOHC, 4.0L 6 cyl MPI
  • Transmission types: NV3550 5-speed Manual, AX15 5-speed Manual, 42RLE 4-speed Automatic
  • Fuel type: Unleaded Gasoline
  • Wheel base: 93.4 in.
  • Transfer cases: NV231, NV241
Technical Specifications
keyboard_arrow_down
Document Number / Seller:
27941 / Sandra Wright
File Size:
57.41 MB
File Type:
PDF
Language:
English
Pages:
2436
Printable:
Yes
Category:
SUV
Last updated / verified
Feb 23, 2025

Jeep Manual Features & Content Preview

2004 Jeep Wrangler TJ Technical Publication Scope

  • Covers 2004 Jeep Wrangler TJ models, including SE, X, Sport, Sahara, and Rubicon variants with 2.4L or 4.0L gasoline engines
  • Official DaimlerChrysler technical publication, original 2004 release
  • Contains 47 exploded-view assembly diagrams and 35 technical torque specification tables for axle, suspension, and drivetrain components
  • File link appears in your order confirmation straight away
  • OCR text layer lets you jump to a torque spec by keyword
  • This 2004 edition is the primary factory reference for the 2004 TJ chassis build, documenting the transition to 42RLE automatic transmissions and NV3550 manual gearboxes

Drivetrain and Suspension Documentation

This manual provides detailed technical information for the 2004 Jeep Wrangler TJ drivetrain and suspension systems. The content includes diagnostic procedures for suspension noise, steering play, and wheel shimmy, alongside comprehensive sections on lubrication, maintenance schedules for both domestic and export models, and heavy-duty towing recommendations. Each section breaks down the disassembly and installation sequences for key components, ensuring that technicians can identify the correct procedures for service operations.

Specification Highlights

Technical data includes specific torque values for suspension arms, track bars, and stabilizer links to maintain vehicle handling precision. Front axle backlash for the 181FBI is specified at 0.12–0.20 mm in the differential setup data. The cooling system capacity for 4.0L engines is documented at 9.9 liters in the fluid specification charts. Cylinder head bolt torque values are documented in a multi-stage sequence, with final-stage angles specified in the engine assembly data. For information on what an OEM service publication covers regarding your specific unit, please refer to our service documentation standards.

An official 2436-page DaimlerChrysler OEM workshop manual covering the 2004 Jeep Wrangler TJ, documenting complete powertrain, chassis, body, and transmission specifications for the LHD and RHD model-year build.

Manual FAQ, Purchase & Download Details

What documentation style and organization markers appear in the 2004 Jeep Wrangler TJ service manual? keyboard_arrow_down

Publication uses specific group designations and a group tab locator to organize technical information. It also includes an alphabetical index at the rear of the manual to assist in locating specific component or system information.

Is there documentation in this manual regarding international control symbols or component displays? keyboard_arrow_down

Introduction section includes a comprehensive chart that lists and explains the various international symbols used for vehicle instruments and display controls.

Are there details regarding fastener identification and torque specifications for the vehicle systems? keyboard_arrow_down

Manual contains dedicated sections for fastener identification that explain how to interpret bolt strength grades and markings. Additionally, it provides specific torque reference charts that cover various fastener sizes and applications.

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