Jeep Grand Cherokee 1999–2004 Repair Manual Set (P/N 81-370-02064)

The DaimlerChrysler service books provide repair procedures, while the diagnostic volumes add symptom-based testing and module-specific fault isolation. The Mopar catalogs support parts identification; the Owner’s Manual covers operation, towing, maintenance, fluids, and safety.

Coverage varies by publication: The service volumes cover 2001 and 2002. The 2004 repair material consists of separate Mitchell system chapters rather than one continuous factory service volume. The 2.7L diesel supplement covers WG applications; the earlier parts catalogs also include 3.1L diesel parts references, which do not establish equivalent repair coverage.

PDF Search, Bookmarks, and Wiring Detail

Finding procedures and circuit labels: Text search is available across the files, but many illustrations and wiring labels are not searchable. Embedded bookmarks organize the service books, diagnostic volumes, diesel supplement, and parts catalogs. The separate 2004 repair chapters, Owner’s Manual, and short reference sheets have no embedded bookmarks. Small wiring labels require zooming, particularly in the dense 2004 circuit diagrams.

The ZIP contains 82 printable PDFs totaling 12,471 pages, including contents pages, indexes, 22 diagnostic notes pages, eight closing comment-form, mailing, and separator pages, and the 14 pages in the three short reference files.

Powertrain Repair, Chassis Service, and Electrical Diagnosis

This selected content preview highlights major workshop areas rather than reproducing the complete contents. Other covered subjects include sunroof service and liftgate repair.

• Engine repair: Step-by-step removal, cylinder-head and valvetrain repair, timing-drive service, internal inspection, lubrication, cooling, fuel delivery, ignition, exhaust, and emissions.

• Automatic transmissions: 42RE, 45RFE/545RFE, and W5J400 diagnosis and service, with internal repair procedures in the applicable service volumes.

• Transfer cases and driveline: NV147, NV242, and NV247 disassembly and assembly, plus propeller-shaft inspection and operating-angle diagnosis.

• Axles and differentials: 186FBI front, 198RBI rear, and 226RBA rear axle repair, including standard, Trac-Lok, and Vari-Lok configurations.

• Chassis and brakes: Link/coil suspension, control arms, track bars, ball joints, knuckles, steering, disc brakes, Teves Mark 20 ABS, adjustable pedals, and alignment diagnosis.

• Electrical troubleshooting: DRBIII routines, DTC and symptom flowcharts, no-start testing, module communication, programming, relearn procedures, connector views, and wiring diagrams.

The diagnostic and overhaul material is suited to technicians and experienced owners familiar with automotive testing; many procedures require a DRBIII scan tool or dedicated service tools.

Engine and Transmission Repair Depth

The gasoline engine sections cover the 4.0L Power Tech I-6 and 4.7L/4.7L H.O. V8. Internal procedures extend to pistons and connecting rods, crankshaft inspection, oil pumps, seals, and component clearances.

The diesel material pairs the 2.7L direct-injection engine with ECM/SKIS diagnosis and W5J400 transmission information.

2004 transmission scope: The automatic-transmission chapter covers 42RE and 545RFE fluid/filter service, linkage, band adjustment, cooler service, and specifications. It is not a complete internal-overhaul volume; deeper repair and diagnostic procedures are in the earlier service books and dedicated transmission publications.

Axle Setup and Transfer-Case Overhaul

Axle procedures cover shafts, seals, bearings, hubs, housings, pinion-depth selection, bearing preload, ring-gear backlash, and tooth-contact checks. Transfer-case chapters extend to chains, sprockets, shift rails, forks, bearings, seals, and case assembly.

The axle instructions explain how incorrect pinion-nut adjustment can over-compress the collapsible spacer and compromise bearing preload.

Module Testing, Wiring, and Parts Identification

The body diagnostic volume covers left- and right-hand-drive systems, PCI-bus communication, airbags, HVAC, the instrument cluster, memory seats, power locks, Remote Keyless Entry, tire-pressure monitoring, theft security, lighting, and wipers.

Powertrain testing includes sensor and actuator checks, pressure-switch diagnosis, quick-learn routines, adaptive functions, and verification tests. Tool references include the DRBIII scan tool, Miller transmission simulator 8333, and numbered installers, removers, and holding tools.

The 2004 wiring chapter contains 56 system diagrams. Examples across the publications include 186FBI Measuring Pinion Gear Depth, Vari-Lok Differential Assembly, NV247 Transfer Case Assembly, Automatic A/C Circuit, Computer Data Lines Circuit, and 4.7L Engine Performance Circuit.

The parts catalogs provide exploded views, part numbers, quantities, VIN/application decoding, and body, trim, powertrain, and driveline codes. This helps distinguish application-specific hardware before parts are ordered.

Suspension and Timing-System Cautions

Suspension sections address final tightening at normal ride height and the effects of bushing preload. The 4.7L timing procedures identify the camshaft target wheel as vulnerable to physical damage and magnetization, either of which can cause a no-start condition.

Before axle, suspension, driveline, SRS, electrical, or HVAC repair, follow the publication’s lift-point, battery-isolation, and refrigerant-handling precautions. Several covered jobs leave the vehicle or heavy assemblies unstable once mounting hardware is removed.

A Preview of 186FBI Axle Setup Specifications

The 186FBI front-axle specifications list ring-gear backlash at 0.13–0.20 mm (0.005–0.008 in.), alongside the related setup and tooth-contact procedures.

Pinion-bearing preload is specified separately for original bearings at 1–2 N·m (10–20 in. lbs.) and new bearings at 1.7–3.4 N·m (15–30 in. lbs.).