2005 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
DESCRIPTION:
2005 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
PAGE NUMBERING :
Two-part page numbers are used throughout this catalog. The first part of the page designatioп indicates one major group or sectюn. The second part indicates the actual page number in the group. For example·
2-1 indicates Group 2, Front Suspension, Page 1
3-4 ind1cates Group 3, Axle Rear, Page 4
In the maintenance of the Loose Leaf Parts Catalog Revisюn Service, it may become necessary to add information beyond the capac1ty of the page. In this event, ап “А” page will Ье used F or example, if it becomes necessary, because of change, to add several part numbers to page 2-1 and space does not perm1t the add1tion, you w1ll Ье given Page 2-lA Page 2-lA should Ье filed immediately followшg Page 2-1.
Figure and Item Numbers are also commonly used to 1dent1fy locatюns m the Catalog, ie , 14-910/8 refers to Group 14, illustratюn 910, Item Numbeг 8. Illustratюп Numbers are always ascendшg sequeпtial
w1thin the Groups
SYМBOLS USED IN THIS CATALOG
The Following symbols are commonly used with Part Number and Quant1ty tnformatюn m this Catalog·
AR – Ind1cates the quantity reqшred may vary or 1s to Ье determined Ьу the user
PAR – Indicates ”Part As Reqшred”
BLANК – Indicates ”All Cond1tion
– = ”Not Illustrated”
LOGICAL ILLUSTRATIONS
Refer to Шustration in front of each group. Тhis will give ass1stance to as how each group 1s broken down and what Spec1fi.c Шustration should Ье referenced
ILLUSTRATION NUМВERING INDEX
Illustration numbers in this Catalog are Group standards. Тhis indicates group and consistent content. ЕХАМРLЕ 8-100 1s а Logical Шustratlon for Starters 8-101 to 8-199 are Specific Шustrations used for Starters for all Catalogs 8-200 will contain Alternators for а11 Catalogs and so 011. Always refer to group index iп froпt of each gгoup.
TABLE OF CONTENTS:
2005 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
2005TJ......................................................................................... 1 Return To Model Year Index................................................................. 0 Return To 2005 Vehicle Family Index........................................................ 0 General Information........................................................................ 1 Abbreviations.......................................................................... 7 Alphabetic Index....................................................................... 6 Body Code Plate Interpretation......................................................... 7 Catalog Groups - Titles & Contents..................................................... 2 How to Use This Catalog and Locate Parts............................................... 5 Illustration Index..................................................................... 6 Illustration Numbering Index........................................................... 5 Index.................................................................................. 1 Logical Illustration Index............................................................. 2 Logical Illustrations.................................................................. 5 Numerical Index........................................................................ 6 Page Numbering......................................................................... 5 Part Packages.......................................................................... 6 Standard Parts......................................................................... 6 Symbols Used in this Catalog........................................................... 5 VIN Plate Decoding Information......................................................... 6 GROUP 001 Component Parts for Mopar Accessories.......................................... 8 FIGURE 001-110 -->Player Kit - CD - Changher - 6 Disc.................................. 9 FIGURE 001-130 -->Navigation Kit (RB1) With RB1 Radio.................................. 10 FIGURE 001-155 -->Satellite Receiver Kit............................................... 11 FIGURE 001-160 -->Install Kit Satellite Receiver Without CD............................ 12 FIGURE 001-220 -->Bike Carrier - Hitch Mount 2 Bikes................................... 13 FIGURE 001-232 -->Ski Carrier - Spare Tire Mount....................................... 14 FIGURE 001-250 -->Trailer Tow - Receiver Kit........................................... 15 FIGURE 001-410 -->Bumper Kit- Front Tubular............................................ 16 FIGURE 001-420 -->Bumper Kit - Rear Tubular............................................ 17 FIGURE 001-440 -->Side Step Kit........................................................ 18 FIGURE 001-510 -->Shield Kit - Air Front............................................... 19 FIGURE 001-550 -->Hardtop Wiring Kit................................................... 20 FIGURE 001-610 -->Light Kit - Fog...................................................... 21 FIGURE 001-630 -->Bar Kit - Light Windshield........................................... 22 FIGURE 001-640 -->Install Kit - Off Road Lights........................................ 23 FIGURE 001-650 -->Heater Kit - Engine Block............................................ 24 FIGURE 001-820 -->Console Kit - Floor.................................................. 25 FIGURE 001-910 -->Alarm - EVS Base System.............................................. 26 GROUP 002 Front Suspension & Drive....................................................... 27 FIGURE 002-110 -->Suspension, Front Spring with Control Arms and Track Bar............. 28 FIGURE 002-120 -->Bar, Front Sway...................................................... 30 FIGURE 002-210 -->Shafts, Front Axle................................................... 31 FIGURE 002-310 -->Housing,Front Axle,4 Wheel Drive..................................... 32 FIGURE 002-410 -->Axle Assembly,Front,4 Wheel Drive.................................... 34 FIGURE 002-610 -->Differential,Front Axle,Without [DSE]................................ 35 FIGURE 002-620 -->Differential,Front Axle,With [DSE]................................... 38 GROUP 003 Rear Axle...................................................................... 40 FIGURE 003-110 -->Axle Assembly, Rear.................................................. 41 FIGURE 003-210 -->Housing,Rear Axle,Dana M35/194MM [DRJ]............................... 42 FIGURE 003-220 -->Housing,Rear Axle,Dana 44/226MM [DRK]................................ 43 FIGURE 003-230 -->Differential,With and Without Trac-Lok [DSA] Dana M35/194MM [DRJ].... 44 FIGURE 003-240 -->Differential,With and Without Trac-Lok [DSA] Dana 44/226MM [DRK]..... 46 FIGURE 003-250 -->Differential,With Trulok Differential [DSE] Dana 44/226MM [DRK]...... 48 FIGURE 003-410 -->Shaft,Rear Axle,Dana 35/194MM [DRJ].................................. 49 FIGURE 003-420 -->Shaft,Rear Axle,Dana 44/226MM [DRK].................................. 50 GROUP 004 Parking Brake.................................................................. 51 FIGURE 004-110 -->Parking Brake Lever and Cables....................................... 52 FIGURE 004-120 -->Parking Brake Assembly,Rear,Disc..................................... 53 GROUP 005 Service Brakes................................................................. 54 FIGURE 005-110 -->Front Brakes......................................................... 55 FIGURE 005-210 -->Brakes,Rear,Disc..................................................... 57 FIGURE 005-220 -->Brakes,Rear,Drum..................................................... 58 FIGURE 005-310 -->Power Brake Booster.................................................. 61 FIGURE 005-410 -->Master Cylinder...................................................... 62 FIGURE 005-510 -->Hydraulic Control Unit,Anti-Lock Brake............................... 63 FIGURE 005-520 -->Brake Lines and Hoses,Front,LHD Without ABS.......................... 64 FIGURE 005-530 -->Brake Lines and Hoses,Front,LHD With ABS............................. 65 FIGURE 005-540 -->Brake Lines and Hoses,Front,RHD,With or Without ABS.................. 66 FIGURE 005-550 -->Brake Lines and Hoses,Rear,Without ABS............................... 68 FIGURE 005-560 -->Brake Lines and Hoses,Rear,With ABS.................................. 69 FIGURE 005-570 -->Rear Axle Brake Sensor Wiring Brackets and Fasteners................. 70 FIGURE 005-610 -->Brake Pedal,LHD...................................................... 71 FIGURE 005-620 -->Brake Pedal,RHD...................................................... 72 GROUP 006 Clutch......................................................................... 73 FIGURE 006-110 -->Clutch............................................................... 74 FIGURE 006-210 -->Attaching Items...................................................... 75 FIGURE 006-310 -->Control, Clutch...................................................... 76 GROUP 007 Cooling........................................................................ 77 FIGURE 007-110 -->Radiator And Related Parts........................................... 78 FIGURE 007-202 -->Water Pump, 2.4L Engine.............................................. 80 FIGURE 007-205 -->Water Pump, 4.0L Engine.............................................. 81 FIGURE 007-310 -->Tank, Coolant Recovery............................................... 82 FIGURE 007-402 -->Drive Pulleys, 2.4L Engine........................................... 83 FIGURE 007-405 -->Drive Pulleys, 4.0L Engine........................................... 84 FIGURE 007-510 -->Drive Belts, 2.4L Engine............................................. 85 FIGURE 007-515 -->Drive Belts, 4.0L Engine............................................. 86 FIGURE 007-610 -->Oil Cooler Lines..................................................... 87 FIGURE 007-705 -->Grille And Related Parts............................................. 88 GROUP 008 Electrical..................................................................... 89 FIGURE 008-105 -->Starter [2.4L Engine]................................................ 91 FIGURE 008-110 -->Starter [4.0L Engine]................................................ 92 FIGURE 008-205 -->Alternator 2.4L Engine............................................... 93 FIGURE 008-210 -->Alternator 4.0L Engine............................................... 94 FIGURE 008-405 -->Modules.............................................................. 95 FIGURE 008-505 -->Power Distribution Center Relays and Fuses........................... 96 FIGURE 008-510 -->Fuse Block........................................................... 97 FIGURE 008-605 -->Sensors 2.4L Engine [ED0]........................................... 98 FIGURE 008-610 -->Sensors Engine 4.0L [ER0]............................................ 99 FIGURE 008-615 -->Sensors, Oxygen 2.4L [ED0]...........................................100 FIGURE 008-620 -->Sensors Oxygen 4.0L [ER0]............................................101 FIGURE 008-625 -->Sensors - Body.......................................................102 FIGURE 008-630 -->Sensors Drive Train..................................................103 FIGURE 008-705 -->Single Board Engine Controllers (JTEC Module)........................104 FIGURE 008-805 -->Switches - Instrument Panel..........................................105 FIGURE 008-810 -->Switches Drivetrain..................................................107 FIGURE 008-815 -->Switches - Body......................................................108 FIGURE 008-905 -->Horns................................................................109 FIGURE 008-1005-->Battery Tray & Cables................................................110 FIGURE 008-1010-->Engine Heaters.......................................................111 FIGURE 008-1105-->Lamps--Front.........................................................112 FIGURE 008-1110-->Lamps--Rear..........................................................114 FIGURE 008-1115-->Lamps--Cargo-Dome-Courtesy...........................................115 FIGURE 008-1120-->Bulbs................................................................116 FIGURE 008-1205-->Wiring--Engine [2.4L Engine].........................................117 FIGURE 008-1210-->Wiring Engine [4.0L Engine]..........................................118 FIGURE 008-1305-->Wiring--Headlamp / Dash Panel........................................119 FIGURE 008-1405-->Wiring Instrument Panel & Fuses......................................121 FIGURE 008-1505-->Wiring--Body & Accessory.............................................122 FIGURE 008-1605-->Wiring Repair Packages...............................................124 FIGURE 008-1705-->Air Bag Modules and Sensors..........................................125 FIGURE 008-1710-->Air Bags and Clock Springs...........................................126 FIGURE 008-1905-->Spark Plugs--Cables--Coil............................................127 GROUP 08A Instrument Panel and Radios and Consoles.......................................128 FIGURE 08A-110 -->Instrument Panel.....................................................129 FIGURE 08A-210 -->Instrument Cluster...................................................132 FIGURE 08A-310 -->Radio................................................................133 FIGURE 08A-320 -->Antenna..............................................................134 FIGURE 08A-330 -->Speakers.............................................................135 FIGURE 08A-410 -->Consoles Full and Mini...............................................136 GROUP 009 Engine Mounting................................................................138 FIGURE 009-110 -->Engine Mounting......................................................139 FIGURE 009-120 -->Transmission Mounting................................................140 GROUP 2.4L Engine 2.4L Four Cylinder.....................................................141 FIGURE 2.4L-210 -->Cylinder Head, 2.4L [ED1]...........................................142 FIGURE 2.4L-310 -->Cylinder Block, 2.4L [ED1]..........................................143 FIGURE 2.4L-410 -->Crankshaft, Pistons and Flywheel, 2.4L [ED1]........................144 FIGURE 2.4L-510 -->Camshaft and Valves 2.4L [ED1]......................................145 FIGURE 2.4L-610 -->Timing Belt and Cover, 2.4L [ED1]...................................146 FIGURE 2.4L-620 -->Balance Shafts, 2.4L [ED1]..........................................147 FIGURE 2.4L-710 -->Engine Oiling, 2.4L [ED1]...........................................148 FIGURE 2.4L-810 -->Intake and Exhaust Manifolds, 2.4L [ED1]............................149 FIGURE 2.4L-910 -->Crankcase Ventilation,204L [ED!]....................................150 GROUP 4.0L Engine 4.0L Six Cylinder......................................................151 FIGURE 4.0L-210 -->Cylinder Head, 4.0L (ERH)...........................................152 FIGURE 4.0L-310 -->Cylinder Block, 4.0L (ERH)..........................................153 FIGURE 4.0L-410 -->Crankshaft, Piston and Torque Converter, 4.0L (ERH).................154 FIGURE 4.0L-510 -->Camshaft and Valves, 4.0L (ERH).....................................156 FIGURE 4.0L-610 -->Timing Cover, 4.0L (ERH)............................................157 FIGURE 4.0L-710 -->Engine Oiling, 4.0L (ERH)...........................................158 FIGURE 4.0L-810 -->Manifold, Intake and Exhaust........................................159 FIGURE 4.0L-910 -->Crankcase Ventilation, 4.0L [ERH]...................................160 GROUP 011 Exhaust........................................................................161 FIGURE 011-110 -->Exhaust System, 2.4 (ED1), 4.0 (ERO).................................162 FIGURE 011-210 -->Heat Shields, 2.4 (ED1), 4.0 (ERH)...................................163 GROUP 013 Frames and Bumpers.............................................................164 FIGURE 013-110 -->Frame................................................................165 FIGURE 013-210 -->Bumper, Front........................................................168 FIGURE 013-310 -->Bumper, Rear.........................................................169 FIGURE 013-510 -->Body Mounting Hardware...............................................170 GROUP 014 Fuel...........................................................................171 FIGURE 014-110 -->Fuel Tank, 2.4 (ED1), 4.0 (ERH)......................................173 FIGURE 014-210 -->Fuel Filler Tube, 2.4 (ED1), 4.0 (ERH)...............................174 FIGURE 014-310 -->Fuel Lines, Front,2.4 (ED1) 4.0 (ERH)................................175 FIGURE 014-320 -->Fuel Lines, Rear, Chassis 2.4L (ED1) 4.0 (ERH).......................176 FIGURE 014-410 -->Fuel Injection System, 2.4 (ED1), 4.0 (ERH)..........................177 FIGURE 014-510 -->Fuel Module, 2.4 (ED1), 4.0 (ERH)....................................178 FIGURE 014-610 -->Throttle Body, 2.4 (ED1), 4.0 (ERH)..................................179 FIGURE 014-710 -->Throttle Controls, 2.4 (ED1), 4.0 (ERH)..............................180 FIGURE 014-810 -->Air Cleaner, 2.4 (ED1), 4.0 (ERH)....................................181 FIGURE 014-1010-->Speed Control, 2.4 (ED1), 4.0 (ERH)..................................182 FIGURE 014-1110-->Accelerator Pedal, 2.4 (ED1), 4.0 (ERH)..............................183 GROUP 016 Propeller Shafts and U-Joints..................................................184 FIGURE 016-110 -->Propshaft,Front and Rear.............................................185 GROUP 017 Rear Suspension................................................................187 FIGURE 017-110 -->Suspension, Rear with Shocks,Springs and Track Bar..................188 FIGURE 017-210 -->Stabilzer, Rear......................................................190 GROUP 019 Steering.......................................................................191 FIGURE 019-110 -->Wheel, Steering......................................................192 FIGURE 019-210 -->Column, Steering Upper and Lower.....................................193 FIGURE 019-310 -->Gear, Power Steering.................................................195 FIGURE 019-410 -->Linkage and Damper...................................................196 FIGURE 019-510 -->Pump, Power Steering.................................................197 FIGURE 019-710 -->Hoses and Reservoir, 2.4L Engine [ED0]...............................198 FIGURE 019-720 -->Hoses and Reservoir,4.0L Engine [ER0]................................199 GROUP 42RLE Automatic Transmisstion 4 Speed..............................................200 FIGURE 42RLE-110 -->Transmission Assembly [DG6].......................................201 FIGURE 42RLE-210 -->Case and Related Parts [DG6].....................................202 FIGURE 42RLE-220 -->Adapter, Rear [DG6] [DG6].........................................203 FIGURE 42RLE-310 -->Oil Pump & Reaction Shaft [DG6]....................................204 FIGURE 42RLE-410 -->Clutch, Input Shaft [DG6].........................................205 FIGURE 42RLE-420 -->Gear Train [DG6]..................................................208 FIGURE 42RLE-710 -->Valve Body [DG6] [DG6]............................................211 FIGURE 42RLE-720 -->Accumulator Piston & Spring........................................212 FIGURE 42RLE-730 -->Parking Sprag [DG6] [DG6].........................................213 FIGURE 42RLE-1210-->Gearshift Controls [DG6]...........................................214 GROUP NSG370 Manual Transmission 6 Speed.................................................215 FIGURE NSG370-110 -->Transmission Assembly [DEH] [DEH]................................216 FIGURE NSG370-210 -->Front Case and Related Parts [DEH]................................217 FIGURE NSG370-220 -->Rear Case and Related Parts [DEH] [DEH]..........................218 FIGURE NSG370-410 -->Input Shaft [DEH] [DEH]..........................................220 FIGURE NSG370-420 -->Main Shaft [DEH] [DEH]...........................................221 FIGURE NSG370-430 -->Countertshaft [DEH]...............................................223 FIGURE NSG370-910 -->Fork and Rails [DEH] [DEH].......................................225 FIGURE NSG370-1210-->Shift Tower [DEH] [DEH]..........................................226 GROUP 231 Transfer Case Model 231........................................................227 FIGURE 231-110 -->Transfer Case [DHN]..................................................228 FIGURE 231-210 -->Case and Related Parts, Command Trac [DHN]...........................229 FIGURE 231-410 -->Gear Train , Command Trac [DHN].....................................232 FIGURE 231-910 -->Forks and Rails, Command Trac [DHN]................................235 FIGURE 231-1210-->Gearshift Controls,Skid Plate, Command Trac [DHN]...................236 GROUP 241 Transfer Case Model 241........................................................238 FIGURE 241-110 -->Transfer Case [DHW].................................................239 FIGURE 241-210 -->Case Transfer and Related Parts [DHW]................................240 FIGURE 241-410 -->Gear Train [DHW].....................................................242 FIGURE 241-910 -->Forks [DHW].........................................................243 FIGURE 241-1210-->Controls and Skid Plate, [DHW]......................................244 GROUP 21P Speedometer Pinions............................................................246 FIGURE 21P-110 -->Speedometer Pinion & Housing.........................................247 GROUP 022 Wheels, Covers and Jacks.......................................................248 FIGURE 022-110 -->Wheels...............................................................249 FIGURE 022-210 -->Caps And Covers......................................................250 FIGURE 022-310 -->Jack And Storage.....................................................251 FIGURE 022-410 -->Wheel, Spare Tailgate Mounted........................................252 GROUP 23D Wiper/Lock Cylinder and Keys...................................................253 FIGURE 23D-105 -->Lock Cylinders and Keys..............................................254 FIGURE 23D-205 -->Wiper System Front...................................................256 FIGURE 23D-305 -->Rear Wiper System....................................................257 GROUP 024 Air Conditioning & Heater......................................................258 FIGURE 024-105 -->Hevac Unit, LHD......................................................259 FIGURE 024-110 -->Hevac Unit, RHD......................................................260 FIGURE 024-210 -->Hoses, Heater 2.4L Engine............................................261 FIGURE 024-220 -->Hoses, Heater 4.0L Engine............................................262 FIGURE 024-225 -->Plumbing, Hevac 2.4L Engine..........................................263 FIGURE 024-235 -->Plumbing, Hevac 4.0L Engine, LHD.....................................264 FIGURE 024-240 -->Pluming, Hevac 4.0L Engine, RHD......................................265 FIGURE 024-245 -->Seals, A/C Condenser.................................................266 FIGURE 024-310 -->Control, Heater And A/c..............................................267 FIGURE 024-410 -->Compressor, Air Conditioning.........................................268 FIGURE 024-610 -->Ducts, Heater And A/c................................................269 GROUP 025 Emission Systems...............................................................270 FIGURE 025-310 -->Vacuum Canister, 2.4 (ED1), 4.0 (ERH)................................271 FIGURE 025-410 -->Emission Control Vacuum Harness, 2.4 (EP1), 4.0 (ERH)................272 FIGURE 025-420 -->Leak Detection Pump, 2.4 (ED1), 4.0 (ERH)............................273 GROUP DTJ Doors and Related Parts........................................................274 FIGURE DTJ-110 -->Door, Full Front Shell And Hinges....................................275 FIGURE DTJ-120 -->Door, Full Front Glass And Regulator.................................276 FIGURE DTJ-130 -->Door, Full Front Lock And Controls...................................277 FIGURE DTJ-160 -->Door, Half Front Shell And Hinges....................................278 FIGURE DTJ-170 -->Door, Half Front Lock And Controls...................................279 FIGURE DTJ-510 -->Mirror, Exterior.....................................................280 FIGURE DTJ-610 -->Door Weatherstrips And Runs..........................................281 GROUP ETJ Exterior Ornamentation.........................................................282 FIGURE ETJ-210 -->Mouldings............................................................283 FIGURE ETJ-310 -->Decals...............................................................284 GROUP ITJ Interior Trim..................................................................285 FIGURE ITJ-110 -->Sunvisors............................................................286 FIGURE ITJ-210 -->Panels, Interior Trim, Front.........................................287 FIGURE ITJ-310 -->Carpets And Interior Trim Panels.....................................288 FIGURE ITJ-410 -->Door Trim Panels Half Doors & Full Doors.............................290 FIGURE ITJ-510 -->Front Vinyl, Trim Code [H6]..........................................291 FIGURE ITJ-520 -->Front, Cloth, Trim Code [P5].........................................293 FIGURE ITJ-530 -->Front, Cloth, Trim Code [S5].........................................295 FIGURE ITJ-540 -->Front, Cloth, Trim Code [Q5].........................................297 FIGURE ITJ-610 -->Rear, Vinyl, Trim Code [H6]..........................................298 FIGURE ITJ-620 -->Rear, Cloth, Trim Code [P5]..........................................300 FIGURE ITJ-630 -->Rear, Cloth, Trim Code [S5]..........................................302 FIGURE ITJ-640 -->Rear, Cloth, Trim Code [Q5]..........................................304 FIGURE ITJ-710 -->Seat Belts...........................................................305 FIGURE ITJ-810 -->Seat Assemblies, Adjusters, Recliners................................307 GROUP STJ Body Sheet Metal Except Doors..................................................312 FIGURE STJ-210 -->Pan, Floor Front And Rear, Body Style 77.............................314 FIGURE STJ-220 -->Pan, Floor Front And Rear, Body Style 78.............................315 FIGURE STJ-310 -->Plugs................................................................316 FIGURE STJ-410 -->Fender And Flare, Front..............................................317 FIGURE STJ-510 -->Hood, Lock, Catches..................................................318 FIGURE STJ-610 -->Panels, Cowl And Dash................................................319 FIGURE STJ-710 -->Glass, Windshield, Backlite, Quarter Windshield Frame, Hinges........320 FIGURE STJ-810 -->Panels, Body Side....................................................322 FIGURE STJ-1110-->Soft Top And Windows.................................................324 FIGURE STJ-1120-->Top Enclosure, Hard..................................................327 FIGURE STJ-1310-->Tailgate.............................................................328 FIGURE STJ-1320-->Add-a-Trunk..........................................................330 FIGURE STJ-1610-->Sport Bar Wrangler...................................................331 GROUP LBLS Labels All Vehicle Locations..................................................333 FIGURE LBLS-110 -->Instrument Panel, Visors and Trim...................................334 FIGURE LBLS-210 -->Engine Compartment..................................................335 FIGURE LBLS-310 -->Doors and Pillars...................................................336 FIGURE LBLS-410 -->Spare Tire..........................................................337 End of Catalog.............................................................................333
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