Jeep Grand Cherokee WJ 2004 Service Manual

• Coverage: 2,333-page PDF for 2004 Jeep Grand Cherokee WJ and WG vehicles, with VIN identification for Sport, Laredo, Limited, and Overland; LHD/RHD, 4x2/4x4, 4.0L, 4.7L, 4.7L HO, and selected 2.7L turbo-diesel applications.
• Gasoline engine repair: diagnosis, engine removal/installation, cylinder heads, valve and camshaft service, timing drives, pistons, crankshaft and bearings, lubrication, oil-pressure testing, inspection limits, and assembly specifications for the 4.0L and 4.7L engines.
• Automatic transmission and transfer case work: 42RE and 545RFE road testing, hydraulic and air-pressure checks, internal teardown, clutch/servo/pump/geartrain/valve-body repair, plus full NV147, NV242, and NV247 disassembly, inspection, reassembly, seal, and shift-cable procedures.
• Axle and driveline coverage: propeller-shaft balance, runout, and operating-angle diagnosis; CV and single/double Cardan joint service; 186FBI, 198RBI, and 226RBA axle repair; Trac-Lok and Vari-Lok diagnosis; pinion-depth, bearing-preload, backlash, and gear-contact-pattern setup.
• Suspension, steering, and brakes: standard and Up-Country caster, camber, toe, and rear thrust-angle tables; hub/bearing and ball-joint replacement; control arms, springs, stabilizer and track bars; steering gear/pump/linkage service and bleeding; base brakes, parking brakes, ABS/HCU service, and scan-tool-assisted ABS bleeding.
• Electrical, body, and HVAC: power distribution, junction block, grounds, PCI bus, fuel/ignition, transmission control, ABS, airbag, lighting, trailer-tow, and body circuits, with connector pin-outs and location views; also doors, liftgate, seats, sunroof, body dimensions, A/C evacuation/charging, and HVAC housing/control repair.

This DaimlerChrysler factory service manual is laid out the same way technicians use it: description, operation, diagnosis, testing, adjustment, removal, installation, disassembly, and assembly. The VIN chart separates WJ and WG vehicles, left- and right-hand drive, 2WD and 4WD, engine family, series, and assembly plant, while individual chapters call out standard versus Up-Country suspension, export equipment, and model-specific electrical hardware.

Powertrain and Chassis Repair Depth

The 4.0L and 4.7L chapters go well beyond tune-up data. They cover mechanical diagnosis, compression/leakage testing, engine removal, cylinder-head and valve service, camshaft/timing-chain work, crankshaft and bearing fitting, piston/ring inspection, oil pump and lubrication diagnosis, manifold service, and final assembly specifications. The 42RE and 545RFE sections include clutch-application charts, hydraulic schematics, road tests, pressure tests, air checks, end-play/clearance data, converter and valve-body service, complete transmission disassembly and reassembly, and component-specific special tools. The NV147, NV242, and NV247 chapters document internal teardown and build-up rather than just fluid changes.

The axle chapters continue at rebuild level. They include propeller-shaft balance/runout diagnosis and angle measurement, axle shaft and seal service, differential carrier removal, pinion-depth shim selection, side-bearing preload, ring-gear backlash, tooth-contact-pattern interpretation, and Trac-Lok/Vari-Lok operational tests. Tool callouts include Inclinometer 7663, Suspension Bushing Remover/Installer 7932, Ball Joint Tool Kit 6289, Dial Indicator C-3339, Pinion Depth Set 6774, and Axle Housing Spreader W-129-B with Adapter Kit 6987B.

Diagnostics, Wiring, and Scope Limits

The dedicated 8W section covers power distribution, junction block circuits, ground distribution, PCI bus communications, charging and starting, gasoline and diesel fuel/ignition, transmission control, ABS, Sentry Key, airbags, HVAC, lighting, trailer tow, power windows/locks/mirrors/seats, splice data, connector pin-outs, and connector/ground/splice location illustrations. Representative technical views include Wheel Alignment Measurements, 42RE/545RFE clutch-application and hydraulic-schematic pages, Vari-Lok oil-feed orientation, gear-tooth contact-pattern charts, and 8W connector-location views.

Important scope note: the 2.7L turbo-diesel/WG configuration appears in vehicle identification, lubricant/capacity data, diesel wiring and pin-outs, power-steering procedures, tire specifications, and A/C component service. The dedicated mechanical engine repair chapters are for the 4.0L and 4.7L gasoline engines, and the complete automatic-transmission overhaul chapters are for the 42RE and 545RFE; NAG1 coverage in this volume is limited to fluid references. DRB III programming and system diagnosis are discussed, but many module-specific DTC pinpoint tests are directed to separate diagnostic publications.

Factory cautions matter on this platform. Rubber-bushed suspension arms must be tightened at normal ride height or the bushings can be preloaded and wear early. A Vari-Lok unit installed with its oil feed tube upward can damage the anti-rotation tabs, and an over-crushed pinion collapsible spacer cannot be corrected by backing off the nut. Ring-gear bolts are treated as one-time-use parts because reuse can lead to fracture and major axle damage.

Across the manual, the repair procedures are backed by component torque charts, fluid specifications and capacities, pressure-test data, electrical values, fit and wear limits, alignment data, body gap/opening dimensions, and sealer and weld-location drawings. Follow the factory warnings for supported vehicle and axle work, spring-loaded components, brake hydraulics, airbag disarming, and refrigerant service, and use the specified tools or calibrated equivalents where called for.