2004 Jeep Wrangler Service and Repair Manual
This factory service and repair manual is matched to the 2004 Jeep Wrangler, so every figure and procedure is correct for your exact engine and trim rather than a generic year range.
Engines
- 2.4L I4 — 148 cu in, DOHC
- 4.0L I6 — 242 cu in, OHV
Trims
- Rubicon
- SE
- Sahara
- Sport
- Unlimited
- X
Known issues on the 2004 Wrangler. Three recalls are on federal record for this model year: a loss of brake fluid that can lower brake line pressure and increase stopping distance, a tire and loading information label fault that leaves the owner without the correct tire, wheel, and inflation pressure information, and a fuel-pump fuel leak that could cause a fire in the presence of an ignition source. Owners have filed 281 complaints and Jeep has issued 33 technical service bulletins for the year. This manual carries the factory diagnostic and repair procedures behind each of those systems.
From a routine service interval to a control-module reflash or a hard-to-trace wiring fault, it keeps you on the OEM procedure and the correct specification for your specific 2004 Wrangler.
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
CERTAIN AFTERMARKET AIRTEX ELECTRIC FUEL PUMPS INSTALLED FOR USE AS REPLACEMENT EQUIPMENT FOR CERTAIN 1997-2004 JEEP WRANGLER; 1997-2001 JEEP CHEROKEE; 1997-2004 JEEP GRAND CHEROKEE; AND 2000-2003 DODGE DAKOTA VEHICLES. THE PLASTIC ELECTRICAL GROMMET CONNECTORS AT THE TOP OF THE FUEL PUMP MODULE ARE NOT COMPATIBLE WITH AUTOMOTIVE FUELS AND MAY DEGRADE CAUSING A POTENTIAL LEAK PATH FOR FUEL.
IN THE PRESENCE OF AN IGNITION SOURCE, A FUEL LEAK COULD RESULT IN A FIRE.
AIRTEX WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE AFFECTED FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 25, 2006. OWNERS MAY CONTACT AIRTEX CUSTOMER SERVICE DEPARTMENT AT 1-800-880-3056.
ON CERTAIN SPORT UTILITY VEHICLES, DUE TO A RECENT SOFTWARE PROGRAMMING ERROR, THE TIRE, WHEEL, AND INFLATION PRESSURE INFORMATION WAS INADVERTENTLY OMITTED FROM THE VEHICLE CERTIFICATION LABEL.
THE VEHICLE OWNER WOULD NOT BE AWARE OF THE TIRE, WHEEL, AND INFLATION PRESSURE INFORMATION FOR THEIR VEHICLE.
OWNERS WILL BE PROVIDED WITH A CORRECTED TIRE CERTIFICATION LABEL. OWNER NOTIFICATION BEGAN ON MARCH 1, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
Plate - Planetary
Security Module Lock Out After Entering the PIN to Unlock The Wireless Control Module (WCM)
KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl
Security Module Lock Out After Entering the PIN to Unlock The Wireless Control Module (WCM)
Malfunction Indicator Lamp (MIL) Illumination. Diagnostic Trouble Codes P0407 ? EGR Sensor B Circuit Low, or P0408 ? EGR Sensor B Circuit High Set
KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl
Valve Body. These may cause over drive cycling.
Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are neces
Showing the 8 most recent of 47 technical service bulletins on file with NHTSA.
THE VEHICLE CAUGHT ON FIRE. *NM THE CONSUMER WAS HIT ON THE PASSENGER SIDE DOOR CAUSING THE OTHER DRIVERS BUMPER TO WEDGE INTO THE CONSUMERS GAS TANK. THE BACK DOOR OF THE CONSUMERS JEEP WAS TORN OFF ALONG WITH THE SPARE TIRE. THE CONSUMERS JEEP DID NOT STOP UNTIL IT FLIPPED OVER. THE CONSUMER STATED THAT THE STURDY JEEP SAVED HER LIFE. THE CONSUMER PURCHASED THE SAME VEHICLE AND THE GAS TANK BLEW UP. THE CONSUMER SON BARELY ESCAPED DUE TO THE FLAMABLE SEATS. THE JEEP BURNED TO THE GROUN
TEXTING DRIVER TURNED INTO MY LANE WITH NO CHANCE TO HIT BRAKES FOR ME WE HIT HEAD ON AT 35 MPH. THE CHEVY IMPALAS AIR BAGS WENT OFF OURS DID NOT . AFTER THE HARDEST HIT OR IMPACT OF MY LIFE WE ROLLED OVER AND LANDED ON THE PASSENGER SIDE WINDSHIELD AND ROLL CAGE , COLLAPSED ON MY WIFE'S HEAD TO LACERATE AND FRACTURE MY WIFE'S SCULL. HAD AIR BAGS WORKED I WOULDN'T HAVE GOTTEN A BROKEN NOSE ON BOTH CODES AND A FRACTURED CHEEK.
I DRIVING MY JEEP AND WAS HIT ON THE DRIVERS SIDE BY A MERCEDES THAT WAS MOVING 35MPH. I WATCH THE WHOLE SCENE COMING THROUGH MY FRONT SOFT TOP GLASS WINDOW. MY FACE HIT THE SOFT TOP WINDOW AND BROKE MY NOSE PRETTY BAD ACCORDING TO DR. CHARLES SHAFFER (MY SURGIEON). BY THE WAY THE SOFT TOP AND UPPER DOOR HALFS WERE THE FACTORY EQUIPPED "WILLY'S EDITION" MODEL SPECIFIC WHICH ARE SUPPLIED TO DAILMER CHRYSLER BY HERTZ. BLOOD WAS EVERYWHERE AND TOOK 3 HOURS TO COMPLETELY STOP THE BLEEDING. I WAS WEA
TL- THE CONTACT OWNS A 2004 JEEP WRANGLER EXTREME. THE CONTACT'S DAUGHTER WAS INVOLVED IN 2 CRASHES , AND THE AIRBAGS DID NOT DEPLOY EITHER TIME. THE CONTACT STATED THAT BOTH OF THE ACCIDENTS HAPPENED WHEN THE ROAD CONDITIONS WERE SLIPPERY AND ICY. *AK
DT*: THE CONTACT STATED WHILE TRAVELING 50 MPH A CAR CUT IN FRONT OF THE VEHICLE, THE DRIVER TURNED THE WHEEL SLIGHTLY AND LOST CONTROL OF THE VEHICLE, THEN STRUCK A GUARD RAIL. THE DRIVER SUSTAINED MINOR INJURIES AND THERE WAS A POLICE REPORT FILED AT THE SCENE. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR SHOP, WHERE IT WAS DETERMINED THE STEERING GEAR SHEERED AND FRACTURED. THE STEERING GEAR NEEDS TO BE REPLACED.
WHILE DRIVING AT 30 MPH VEHICLE HIT A TREE HEAD ON. UPON IMPACT, FRONTAL AIR BAGS FAILED TO DEPLOY. CONSUMER HIT THE STEERING WHEEL, AND SUSTAINED A CUT AND BRUISES ABOVE RIGHT EYE. *AK *LA
HIT A REGULAR BUMP IN THE ROAD, AT 35 MILES PER HOUR ON A STRAIT STRETCH OF ROAD AND THE ATTACHMENT POINT FOR THE FRONT SUSPENSION PULLED AWAY FROM THE FRAME AND I LOST CONTROL OF THE JEEP, UPON FURTHER INSPECTION I DISCOVERED THAT THE ENTIRE CENTER SECTION OF THE FRAME IS RUSTED FROM THE INSIDE OUT ON BOTH SIDES, THE FRAME SHOULD BE THE LAST THING TO FAIL ON ANY VEHICLE, THIS JEEP HAS ONLY 65,000 MILES ON IT AND HAS NEVER BEEN OFF ROADED OR ABUSED. FOR A VEHICLE THAT IS KNOWN TO LAST 200K MILES
WHILE DRIVING AT 25 MPH CONSUMER'S VEHICLE WAS HIT BY ANOTHER VEHICLE ON THE FRONT DRIVERS SIDE. UPON IMPACT, BOTH FRONTAL AIR BAGS DID NOT DEPLOY. DRIVER SUSTAINED MINOR INJURIES. *AK
TL* THE CONTACT OWNS A 2004 JEEP WRANGLER. THE CONTACT STATED THAT WHILE TRAVELING AT AN UNKNOWN SPEED, THE DRIVER ATTEMPTED TO AVOID CRASHING INTO A DEER AND LOST CONTROL OF THE VEHICLE. THE VEHICLE ROLLED OVER AND THE DRIVER'S SIDE SEAT BELT BECAME SEPARATED FROM THE BELT CLIP. THE DRIVER WAS EJECTED FROM THE VEHICLE AND SUFFERED FROM FATAL INJURIES. A POLICE REPORT WAS FILED OF THE INCIDENT. THE VEHICLE WAS TOWED TO THE CONTACT'S HOME AND HAD NOT BEEN INSPECTED TO DETERMINE THE CAUSE OF THE
MY DAUGHTER EXPERIENCED BRAKE FAILURE IN HER 2004 JEEP WRANGLER CAUSING HER TO COAST THROUGH A STOP SIGN AND HIT AN ONCOMING CAR. UPON INSPECTION OF HER JEEP, THERE WAS A CLIP MISSING THAT SECURED THE CONNECTION OF THE BRAKE PEDAL ASSEMBLY TO THE ACTUATOR ROD THAT GOES INTO THE BRAKE BOOSTER/MASTER CYLINDER. WITHOUT THE CLIP, THE TWO PARTS SEPARATED CAUSING COMPLETE BRAKE FAILURE. THIS CAR HAS NO HISTORY OF BRAKE REPAIR IN THAT AREA WHICH INDICATES A FAULTY CLIP OR A CLIP WAS NEVER INSTALLED FR
DT*: THE CONTACT STATED THE PITMAN ARM FELL OFF FROM THE STEERING GEAR BOX WHILE DRIVING 20 MPH ON NORMAL ROAD CONDITIONS, CAUSING THE VEHICLE TO SIDESWIPE ANOTHER VEHICLE. NO INJURIES WERE SUSTAINED, AND A POLICE REPORT WAS TAKEN. THE VEHICLE WAS TOWED TO THE DEALER FOR EVALUATION. ALSO, THE FRONT END SHOOK WHEN DRIVING 50 MPH FOR TWO MONTHS PRIOR TO THE FAILURE. THE MANUFACTURER WERE CONTACTED BUT THE CAUSE OF THE PROBLEM COULD NOT BE DETERMINED.
TL- THE CONTACT OWNS A 2004 JEEP WRANGLER. THE CONTACT STATED THE WHILE DRIVING 45 MPH DOWN A STEEP HILL WHEN THE BRAKES FAILED. THERE WERE NO WARNING LIGHTS THAT ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT VEERED THE VEHICLE TO THE RIGHT. THE VEHICLE WAS WAS STEERED ALONG SIDE A FENCE, IN ORDER TO SLOW THE VEHICLE DOWN. THE CONTACT CRASHED INTO A TREE IN ORDER TO STOP THE VEHICLE. THE TWO FRONT AIR BAGS DID DEPLOY. THERE WERE NO REPORTED INJURIES. THE VEHICLE WAS TOTALED. THE VEHIC
TL* THE CONTACT OWNED A 2004 JEEP WRANGLER. THE CONTACT STATED THAT WHILE EXITING HER DRIVEWAY CARPORT GOING 10 MPH, WITHOUT WARNING THE VEHICLE ACCELERATED AND THE CONTACT COULD NOT CONTROL THE STEERING WHEEL WHICH SEIZED. THE CONTACT ATTEMPTED TO DEPRESS THE BRAKES WHICH FAILED CAUSING, THE CONTACT TO CRASH INTO THE CARPORTS POLE ALLOWING THE VEHICLE TO COME TO A COMPLETE STOP. NO EMERGENCY BRAKE WAS APPLIED. NO INJURIES, NO POLICE REPORT FILED, NO MEDICAL ATTENTION, NO DAMAGE'S TO THE VEHICLE
MY 2004 JEEP WRANGLER WAS IN PARK AND RUNNING AND DRIFTED DOWN A HILL AND INTO ANOTHER PARKED VEHICLE CAUSING 4K WORTH OF DAMAGE TO MY JEEP AND WHO KNOWS HOW MUCH TO THE OTHER VEHICLE. THERE IS A RECALL ON 2005 AND 2006 JEEP WRANGLERS FOR TRANSMISSION "PARK" PROBLEMS, I THINK THEY ARE MISSING A YEAR! *TR
MY 16 YEAR OLD DAUGHTER WAS DRIVING THE VEHICLE ON NORMAL DRY PAVEMENT WHEN THE CASTING THAT ANCHORS THE TIE ROD TO THE FRONT LEFT WHEEL SNAPPED OFF. THE VEHICLE VIOLENTLY PULLED TO THE RIGHT CAUSING IT TO GO OFF THE PAVED ROAD SURFACE AND CRASHING INTO A TREE. THE VEHICLE HAS THE ORIGINAL FACTORY SUSPENSION AND TO MY KNOWLEDGE HAS NEVER BEEN MODIFIED.
Showing the 15 most serious of 192 complaints filed with NHTSA.
