Jeep UNIVERSAL CJ-2A Service Manual Download

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Summary of Contents for UNIVERSAL CJ-2A

Page 1: ...SERVICE MANU AL FOR UNIVERSAL _ Jeep VEHICLES 0 0 1 0 t 1...

Page 2: ...CORPORATION NOW JEEP CORPORATION REPRINTED BY PERMISSION OF COPYRIGHT OWNERS SECTION INDEX Name Section General Data A Lubrication B Tune Up c L Head Engine D F Head Engine E FuelSystem F Exhaust Sys...

Page 3: ......

Page 4: ...s ap proved fdr publication Significant changes made in each model sitice it was first produced are in cluded in the manual A description of each model follows General specifications for each model ar...

Page 5: ...erial Number The engine identification number consists of a prefix followed by a five digit or six digit serial number The prefix identifies the particular engine F4 134 and L4 134 engine serial numbe...

Page 6: ...AXLE MODEL NUMBER LOCATION A 9 Carburetor Carburetors are identified by the manufacturer s model number stamped or cast into the carburetor body as shown in Fig 6 FIG 6 CARBURETOR MODEL NUMBER LOCATI...

Page 7: ...COIL MODEL NUMBER LOCATION A 13 Distributor Ignition distributors are identified by the manu factprer s model number stamped on a plate at tached to the distributor housing as shown n Fig 10 FIG 10 D...

Page 8: ...ied by a manufacturer s model number stamped on a metal tag attached to the motor housing as shown in Fig 12 FIG 12 STARTING MOTOR MODEL NUMBER LOCATION A 16 Voltage Regulator Voltage regulators are i...

Page 9: ...114 lb ft 15 7 kg m 80 203 em 48 6 123 em 66 169 em 1292 2 3 30 m 68Ys 175 em 8 20 3 em 2132 lb 967 1 kg 2243 lb i017 4 kg 3500 lb 1587 5 kg 1072 gal 38 75 ltr 11 qt 10 4 ltr 12 qt 11 4 ltr CJ 3A L H...

Page 10: ...eed through seals always use sodium base SUBJECT PAR King Pin Bearings B 11 Lubrication Fittings B 8 B 41 Oil Filter B 22 B 42 Oil Pressure B 4 Power Take Off B 47 Propeller Shaft U Joints B 10 Radiat...

Page 11: ...C I use SAE 20 20W lOW 30 or lOW 20 QUANTITY i LUBRICANT GRADE u s Imperial Metric TYPE Summer I Winter As required Chassis Lubricant No 1 No 0 4 qts 3 i qts 3 785ltrs Engine Oil See Note 3 Y pts 3 p...

Page 12: ...Check each 1000 miles 6 4 pts 5 4 pts 3 2 ltrs GL4 SAE 90 SAE 80 Transfer Case tChange each 10 000 miles 3 pts 3 pts 1 7 ltrs GL4 SAE 90 SAE 80 Differentials 1 Front Check each 1000 miles I 2 7li pts...

Page 13: ...miles Each 1000 miles Chan e each 2000 miles 0 0 As low as 1l l F 12 C use SAE 20 20W lOW 30 or lOW 20 QUANTITY I LUBRICANT GRADE u s fmperial Metric TYPE I Summer Winter As required Chassis Lubricant...

Page 14: ...ighten drain plug e Check for presence of excess water in the oil that might indicate an internal leak from the cooling system B 8 Lubrication Fittings Each 1000 miles 1 600 km clean each lubrication...

Page 15: ...ck level each 1000 miles 1 600 km and add lubricant when necessary Drain and refill housing each 10 000 miles 16 000 km j B 17 Optional 4 Speed Transmission emd Transfer Case Models CJ 5 and CJ 6 The...

Page 16: ...Agitate the cleaner body thoroughly in cleaning solution to clean the filtering element Dry element with air hose but do not re oil Install the cleaner body in the vehicle with the two wing screws an...

Page 17: ...mp and clutch release bearings are 16 prelubricated for life when manufactured and cannot be relubricated B 36 Starting Motor Bearings e Models CJ 3A S N 30972 and on CJ 3B CJ 5 CJ 6 DJ 3A The startin...

Page 18: ...se The combined capacity of the two housings is small for economy making it important that the lubricant be changed at regular intervals For heavy duty farm or industrial work drain both housings ever...

Page 19: ......

Page 20: ...of time will be seriously damaged c Check the wing nuts on the hold down frame for tightness Tighten them only with finger pres sure never with pliers or a wrench Excessive pressure could damage the b...

Page 21: ...ot overlook tightening the cylinder head bolt No 5 in the intake manifold directly under the carburetor opening Torque all manifold attaching nuts evenly to 30 to 35 Ib ft 4 1 a 4 8 kg m 20 10102 FIG...

Page 22: ...be replaced Clean any corroded high tension terminals b Inspect the rotor for cracks or evidence of excessive burning at the end of the metal strip After a distributor rotor has had normal use the en...

Page 23: ...insulation will permit cross firing or missing of the engine defective wires should be replaced 22 C 12 Service Air Cleaner Clean and refill the air cleaner See Par B 23 C 13 Check Fuel Line and Scre...

Page 24: ...take port or an electrical miss e An intermittent pulsating reading is caused by an occasional malfunction such as a sticking valve all valves may be erratic in operation if the valve springs are weak...

Page 25: ...orrect Clogged Exhaust System Valves Sticking Warped Valve 24 Improper Tappet Clearance Carbonized or Scored Valve Stems Insufficient Clearance Valve Stem to Guide Valves Sticking Continued Weak or Br...

Page 26: ...Location L4 134 F4 134 Compression Pressure Cranking L4 134 F4 134 Valves Tappet Clearance Cold Intake L4 134 F4 134 Exhaust L4 134 F4 134 Timing Intake Opens Engine Idle Speed Firing Order 6 or 12 Vo...

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Page 28: ...nt production engines is gear driven from the crank shaft chain driven on early production engines SUBJECT PAR Inspection and R epair D 28 Manifolds D 8 D 92 Oil Filler Tube D 9 D 93 Oil Filter D 102...

Page 29: ...ring Cover 6 Heat Control Valve 7 Crankcase Ventilator Gasket 8 Exhaust Manifold 9 Crankcase Ventilator 10 Distributor Shaft Friction Spring 11 0il Pump Driven Gear 12 0il Pump Gasket 13 0il Pump 14 0...

Page 30: ...nits m Disconnect the exhaust pipe from the exhaust manifold n Remove the two nuts and bolts from each front engine support and remove the supports This will allow the engine to drop slightly and will...

Page 31: ...crankcase vent body and the engine ventilating system parts threaded to it Remove the valve cover plate screws and the valve cover plate D 14 Remove Cylinder Head Remove the spark plugs Remove the cyl...

Page 32: ...aft with two tapered dowel bolts and four special bolts Remove these attaching parts Use a pry bar between the flywheel and the back of the engine and carefully loosen the flywheel from the crankshaft...

Page 33: ...ons are provided Inspection and repair instructions are included to cover the 32 cylinder block cylinder head crankshaft and bearings connecting rods and bearings oil pump valves and tappets pistons a...

Page 34: ...ove the top rit1g which acts as a heat dam or insulating groove to protect against sealing of the top ring in the ring groove with hard carbon The piston pin is secured by a lock screw The pistons and...

Page 35: ...ins are anchored in the rods with lock screws Installatidn of oversize pins in this engine is not recommended as experience has shown that should a pin be worn sufficiently to require replace ment the...

Page 36: ...ust be as shown in Par D 34 for all rings If less file ends to obtain minimum gap With cylinders bored to an exact ring oversize of 020 030 or 040 0 508 0 762 1 016 mm the proper end clearance as in d...

Page 37: ...tural flaws Cracks misalignment and scored or worn journals and crankpins necessitate crankshaft repair or replacement 36 Check crankshaft counterweights to be sure they are not loose D 37 Checking Cr...

Page 38: ...t Main Bearings Fit the crankshaft main bearings using either Plastigage or shim stock Refer to the instruc tions in Section E for Plastigage Par E 46 or shim stock Par E 47 I D 44 Connecting Rod Bear...

Page 39: ...rod side play with a feeler gauge as shown in Fig 45 The side clearance is 004 to 010 0 1016 a 0 254 mm D 48 o mshaft and Bearings The camshaft is supported at four points in the cylinder block The f...

Page 40: ...The valves seat on top of the cylinder block with the stems extending down through replaceable valve guides The valves are actuated by the cam shaft through valve tappets The valve springs are assembl...

Page 41: ...on and Refacing Inspect the valve seats for cracks burns pitting ridges or improper angle During any general engine overhaul it is advisable to reface the valve seats regardless of their condition If...

Page 42: ...hould it be necessary to replace the guides this in stallation can b t be made by using Valve Guide Driver tool W 238 as shown in Fig 49 The old guides are removed by driving them through the block in...

Page 43: ...o install the pump without dis turbing the timing the pump gear must be cor rectly meshed with the camshaft driving gear to allow engagement of the key on the distributor shaft with the pump shaft slo...

Page 44: ...to Body Screw Gasket 3 Cover Plug 4 Cover 5 Pinion 6 Rotor Disc 7 Shaft Assembly 8 Shaft Gasket 9 Cover Gasket 10 Qil Pump to Block Gasket 11 Driven Gear Pin 12 Driven Gear 13 0il Pump Body 14 0il Re...

Page 45: ...acing the ring gear place the new ring gear against the old gear to make certain both have the same number of teeth To remove the ring gear from the flywheel drill a 9 5 mm hole through the ring gear...

Page 46: ...y in the bearings Do not allow the rear end of the cam shaft to strike sharply against the expansion plug installed in the rear end of the bore Install the camshaft thrust plate Slide the thrust plate...

Page 47: ...gear or sprocket onto the crank shaft firmly against the thrust washer D 77 Install Crankshaft Rear Bearing Seal On early L4 134 engines the crankshaft rear bear ing is sealed by a wick packing This...

Page 48: ...the nuts alternately and evenly until each is tightened 35 to 41 lb ft 4 8 a 5 7 kg m After installation check the run out of the flywheel with a dial indicator attached to the engine plate as illust...

Page 49: ...e right side of the engine Fig 67 and Fig 68 Place the camshaft sprocket on the shaft and tum the shaft until the punch mark on the rim of the sprocket faces the punch mark on the crankshaft sprocket...

Page 50: ...f the capscrews with gasket cement and secure the oil pump in place with two lockwasher equipped capscrews installed through the body of the oil pump and into the cylinder block and one lockwasher cap...

Page 51: ...lternately and evenly 12 to 17 lb ft 1 7 a 2 3 kg m D 95 Install Water Outlet Fitting Install the thermostat and the water outlet fitting Torque the water outlet fitting attaching bolts 20 to 25 lb ft...

Page 52: ...th engine S N 175402 and on model CJ 3A before engine S N 13085g top center and 5 before top center are marked on the flywheel as shown in Fig 68 On model CJ 3A beginning with engine S N 1308Sg and al...

Page 53: ...nd the oil level gauge or dip stick in the side of the engine provide a means for checking the oil pressure and oil level D 101 Crankcase Vent ilation e Models CJ 2A CJ 3A and DJ 3A The crankcase vent...

Page 54: ...nce Sticking Vahres_ Valve Timigg LGJ te Leaky Gaskets Muffler Clogged Bent Exhaust Pipe Defective Spark Plugs Clean or Replace bers Poor Valve Seating Sticking Valves Broken Valve Spring Tappets Adju...

Page 55: ...ON PINS MateriaL Type Clearance in Piston selective fit CONNECTING RODS Material Weight Length center to center Bearing Type Material Length Over All Ciearance Limits Undersize Bearings Available Jtnd...

Page 56: ...ntake CJ 2A CJ 3A DJ 3A OOi Froin Above SUS to 8125 2 0432 to 2 0440 SAE 1040 Forged Steel Front Bearing 004 to 006 Removable Steel backed Babbitt 0003 to 0029 2 3331 to 2 3341 001 002 010 012 020 030...

Page 57: ...Reli f V a1y Q el l s 1 N ormli Ou r stir Otl Pressure Send i g Umt Oil Intake Oil Filter System J t 1 1 L4 l34 ENGINE CJ 2A CJ 3AtDJ 3A 373 OOOJ to 0022 351 H rniloy l 12 5 7g J 47 H 45 lt J to ite E...

Page 58: ...timing gears etc Cylinder walls and piston pins are i SUBJECT PAR Inspection and Repair E 31 Manifold E 8 E 102 Oil Filler Tube E 9 E 103 Oil Filter E 112 O IPan E 18 E 68 E 98 0 0 1 1_Pumsp E 13 E 67...

Page 59: ...10 Exhaust Valve Guide 11 Exhaust Manifold 12 Exhaust Valve Spring 13 Crankcase Ventilator 14 0il Pump Gear 15 C lmshaft 16 0il Pump 17 Relief Plunger 18 Relief Plunger Spring 19 Relief Spring Retaine...

Page 60: ...alve Guide 23 Exhaust Manifold 24 Exhaust Valve Spring 25 Cylinder Block 26 Piston Pin 27 Exhaust Tapp t Adjusting Screw 28 Engine Rear Plate 29 Camshaft 30 Flywheel 31 Crankshaft Rear Bearing Seal 3...

Page 61: ...side of the cylinder block b Disconnect the battery at the positive terminal to avoid the possibility of short circuit 60 c Remove the air cleaner horn from the carburetor and disconnect the breather...

Page 62: ...aft nut Install a puller and pull the pulley from the crankshaft E 13 Remove Oil Pump The oil pump is located externally on the left side of the engine If only the oil pump is being removed with the e...

Page 63: ...same guides from which they are removed Note Check the condition of the rubber 0 rings Defective 0 rings could be the major cause of oil leakage into cylinders Always discard and replace all 0 rings...

Page 64: ...f the engine and carefully loosen the flywheel from the crankshaft If the flywheel is to be removed with the engine in the vehicle the transmission and clutch must first be removed as detailed in Sect...

Page 65: ...Bearing Set 30 Exhaust Valve 31 Exhaust Valve Guide 32 Cylinder Block 33 Cylinder Block Drain Lock 34 Tappet Adjusting Serew 35 Exhaust Valve Tappet 36 Crankshaft Rear Bearing Seal 37 Crankshaft Bear...

Page 66: ...distortion by placing a straight edge along the length of the cylinder head surface of the block With a feeler gauge check for clearance between the straight edge and the block particularly be tween a...

Page 67: ...mm 1 016 mm Disassemble the pistons and rods Remove the two compression rings the oil control ring and the oil control ring expander from each piston Do not remove the bolts from the lower end of the...

Page 68: ...ds of soft metal or two pieces of hardwood one on each side of the rod and positioned approximately 3 76 1nm from the piston pin end Start the piston pin in the piston with the lock screw groove facin...

Page 69: ...ntrol rings Production type replacement piston rings are the same as the original factory installed rings while service oil control ring sets have different com ponents notably the oil ring expander F...

Page 70: ...001 11 0 0254 mm E 42 Checking Connecting Rod Crankpins Check the crankpin diameters with a micrometer to ensure that they are not out of round or tapered more than 001 11 0 0254 mm The standard cran...

Page 71: ...rnal E 47 Fitting Crankshaft Main tsearings Using Shim Stock Thin feeler or shim stock may be used instead of Plastigage to check bearing clearances The method is simple but care must be taken to prot...

Page 72: ...running fit difference between the diameter of the crankpin and the inside diameter of the fitted bearing for a connecting rod bearing is 003 to 0025 0 0076 a 0 0635 mm With a dimension in excess of t...

Page 73: ...crank haft by a nut threaded onto the front end ofthe crankshaft holding the crank 72 shaft pulley crankshaft oil slinger and l he crank shaft drive gear spacer The timing gears are lubricated throug...

Page 74: ...e exhaust valve stem diameter is 371 to 37Z 9 423 a 9 449 mm FIG 90 VALVE WITH ROTO CAP Note Exhaust and intake valve springs are similar in appearance They must not be inter changed as they have diff...

Page 75: ...necessary to reface the valve seats use a valve seat grinder in accordance with the grinder manufacturer s instructions Any grinding of valve seats should be preceded by touching up the grinding ston...

Page 76: ...ositioned the top end of the guide is exactly 1 25 4 mm below the level of the top of the block as shown in Fig 94 Start a new intake valve guide tapered end first into position from the bottom of the...

Page 77: ...externally on the left side of the engine In operation oil is drawn from the crankcase through the floating oil intake then passes through a drilled passage in the crankcase to the pump from which it...

Page 78: ...it is flat within 001 11 0 025 mm tested with feeler gauges Fig 99 Measure thickness of the rotors which musfbewithin 001 11 of each other Assemble the rotors in the pump body and install the cover wi...

Page 79: ...er the teeth are broken cracked or seriously burred the ring gear should be replaced E 71 Ring Gear Replacement The ring gear is secured on the flywheel by a shrink fit Before starting the operation o...

Page 80: ...d their related parts are mounted on the top of the cylinder head and en closed by the rocker arm cover The rocker arm shaft supported in four rocker arm shaft brackets carries the rocker arms and the...

Page 81: ...the en ine and its parts against d i ma e ote With the adoption of the 4 starting D lotor a new flyWheel housing rear engine plate and fly Vheel ring gear were required E so lnstaJI Oil all ry Plug Co...

Page 82: ...their respective bearing caps NOTE It is possible to incorrectly install the front main bearing The bearing is properly installed in the cap with the narrower of the two radial oil grooves toward the...

Page 83: ...flywheel in proper relation then install the straight bolts previously used and tighten securely Next use the l 4 13 9 mm drill to enlarge the tapered holes Ream the holes with the VJ6 14 3 mm straigh...

Page 84: ...usting screw Make certain tha t the two clbsely wound coils of each spring are at the to_p_ p la ced up to seat ljlg inst the block See i ig 107 Turn the c cranksha ft as necessary to bring each exhau...

Page 85: ...lled through the body of the oil pump and into the cylinder block and one lockwasher capscrew installed through the oil pump mounting flange 84 E 95 Install Timing Gear Cover Apply a thin coat of gask...

Page 86: ...l the pump in position on the cylinder block Torque the water pump attaching bolts alternately and evenly 12 to 17 lb ft 1 7 a 2 3 kg m E 105 Install Water Outlet Fitting Install the thermostat and th...

Page 87: ...such as a leak at the carburetor gasket late ignition or valve timing or uniform piston ring and bore wear e A slowly fluctuatine or drifting reading indicates that the idle mixture is incorrect and t...

Page 88: ...onsumption that is normal for the driving habits and type of operation involved should be evident at 4000 miles E 111 Positive Crankcase Ve11tilation The crankcase ventilating system provides thor oug...

Page 89: ...or too Loose in Guides Improper Timing Excessive Carbon Around Valve Head and Seat Overheating Valve Spring Weak or Broken 88 Burned Valves and Seats continued Valve Tappet Sticking Valve Tappet Clear...

Page 90: ...g No 2 Ring No 3 Ring PISTON PINS Material Length Diameter Type Clearance in Piston selective fit CJ 3B CJ 5 CJ 6 F Head 4 3Ys 4 134 2 cu in 3 437 4 938 1 3 4 2 7 4 1 6 9 1 120 to 130 psi 2 1 15 63 75...

Page 91: ...9 187 Removable Steel backed Babbitt 1 089 to 1 099 001 to 0019 001 002 010 012 020 030 004 to 010 From Above 8115 to 8125 2 0432 to 2 0440 SAE 1040 Forged Steel Front Bearing 004 to 006 Removable Ste...

Page 92: ...Tappets Timing Gears Cylinder Walls Oil Pump Type Drive Minimum Safe Oil Pressure At Idle At 2000 rpm 35 mph Relief Valve Opens I Normal Oil Pressure I Oil Pressure Sending Unit 1 Oil Intake i Oil Fil...

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Page 94: ...4 5 ltr of gasoline will dissolve any deposits as it passes through the system with the gasoline SUBJECT PAR Metering Rod Adjustment F 20 Servicing and Adjusting F 8 Steep Grade Carburetor Kit F 28 F...

Page 95: ...le valve seat assembly The float circuit Fig 114 is important because it controls the heights of the fuel level in the bowl and 94 FIG 114 FLOAT CIRCUIT 1 Needle Valve Seat Assembly 2 Float and Lever...

Page 96: ...ig 116 cuts in as the throt tle is opened wide enough for a speed of about 20 miles per hour 32 k p h The velocity of the air flowing down through the carburetor throat creates a pressure slightly les...

Page 97: ...over in position as shown the float by its own weight should rest at 9 525 mm as indicated by the gauge To change the float level press down with a screw driver on the brass lip of the float holding u...

Page 98: ...djust the metering rod back out throttle lever adjusting screw C Fig 120 and close the throt tle tight Using gauge T 109 26 Fig 120 sup plied by Carter Carburetor Co loosen nut B and move pin until it...

Page 99: ...criptions and repair procedures given in the following paragraphs apply equally to all YF series carburetors YF series carburetors employ manual and vacuum control of the metering rod and accelerator...

Page 100: ...ring Rod 3 Pump Lifter Link 4 Metering Rod Arm Assembly 5 Diaphragm Shaft 6 Upper Pump Spring 7 Pump Diaphragm Spring 8 Diaphragm Assembly 9 Chamber 10 Metering Rod Jet 11 Carburetor Casting 12 Carbur...

Page 101: ...running Lower and more uniform vacuum is provided by vacuum restriction and vacuum bleed passage When the diaphragm is in its maximum down position at low throttle resulting from high vacuum in chambe...

Page 102: ...intake strainer housing using tip of knife blade h With the air horn in an upside down position remove pin and float Invert the air horn and catch needle pin and needle pin spring FIG 128 CARBURETOR...

Page 103: ...mp lifter link hole CAUTION Linkage must not bind in any throttle position If binding occurs loosen clamp screw in throttle arm adjust slightly then retighten screw m Install pump check disc disc reta...

Page 104: ...CJ 2A DJ 3A Fig 130 illustrates the pump used on the Models CJ 2A and DJ 3A The rotation of the camshaft eccentric operating rocker arm pivoted at the rocker arm pin pulls the link and diaphra m as se...

Page 105: ...ut the diaphragm assembly in place Install inlet valve assembly with new gasket The inlet valve is installed in the body with the spring facing down Install the outlet valve assembly with the outlet v...

Page 106: ...them mly with the cover plate screw F 35 Fuel Pump Testing Correct fuel pump pressure 1s essential to satis factory engine performance Pressure that is too low will affect proper carburetion Pressure...

Page 107: ...Also operating ecr momy 105 would be affected because a high fuel level usually results in an over rich mixture The actuating linkage has its own spring to ensure continuous contact of the lever to th...

Page 108: ...s up evenly and securely Install the filter screen cork gasket and sediment bowl and secure them firmly with the thumb screw on the bowl clamp F 42 Vacuum Pump Models CJ 3B C 5 C 6 The double action f...

Page 109: ...p In addi tion check the following a Check for secure mounting of the fuel pump The rocker arm may be working the entire pump up and down rather than just the pump dia phragms b Remove and clean the f...

Page 110: ...arburetor throttle valve is wide open the accelerator treadle will just strike the toe board After correct ad justment is made tighten both lock nuts firmly On Models CJ 2A and CJ 3A adjust the linkag...

Page 111: ...Engine Hesitates on Acceleration Accelerator pump does not function perfectly Replace piston and rod or adjust Carburetor float level Adjust Spark plugs Replace or clean and adjust Low compressiou Ch...

Page 112: ...e Accelerating Pump Discharge Jet Intake Ball Check Discharge Check Relief Passage Stroke Stroke Setting Gauge Air Cleaner Make Model Type Oil Capacity CJ 2A CJ 3A 10 2 gals Under Driver s Seat AC 153...

Page 113: ...a to 1 turns open No 74 0225 drill 07325 X 0655 X 057 X 04725 0935 dia No 68 031 drill No 72 025 drill No 42 0935 drill No 55 052 drill No 65 035 drill 054 to 056 dia Oil Bath Donaldson FAE OG 5351 1...

Page 114: ...valve bushings are lubricated proper operation of the valve should be checked When assembling the manifolds to the cylinder block new gaskets should be installed and the nuts drawn up evenly until the...

Page 115: ...e tail pipe or muffler as these can cause faulty engine performance FIG 137 EXHAUST PIPE AND MUFFLER 1 Exhaust Pipe 2 Ciamp 3 Exhaust Pipe Extension 4 Ciamp 5 Tail Pipe 6 Muffter 7 Ciamp 8 Support Str...

Page 116: ...connection at the top of the engine Turn the water on and fill the water jacket and then apply air in short blasts Continue this flushing until the water runs clear Also do the hot water heater Remov...

Page 117: ...esulting from extreme temperature 1 hanges can aggravate leaks For hese reasons when checking for coolant leaks in 1pect the biock when it is cold and while the rengine s runntng A leaking drain f ock...

Page 118: ...away from any possible interference with the governor belt H 9 Heat Indicator The unit used on Models CJ 2A 3A and early 3B is of the Bourdon or hydrostatic type and is con nected by means of a capill...

Page 119: ...he drive of the V belt is on the sides of the V A 118 FIG 139 WATER PUMP 1 Fan and Pump Pulley 2 Bearing and Shaft 3 Bearing Retainer Spring 4 Pipe Plug 5 PumpBody 6 8eal Washer 7 Pump Seal 8 Impeller...

Page 120: ...d fresh air heaters The heater controls are operated manually through Bowden cables Late production vehicles are equipped with vacuum operated fresh air heaters that are operated by and identified by...

Page 121: ...J 5 CJ 6 DJ 3A Length CJ 2A CJ 3A CJ 3B CJ 5 CJ 6 DJ 3A Width ANTIFREEZE Quarts Quarts u s Imperial 2 1 3 2Y2 4 3 5 4U 6 5 2 1 3 2H 4 3 5 4 4 6 5 120 Liters 2 2 3 4 5 2 2 33h 4 5 I I Under Hood 4 Y l...

Page 122: ...ntion At each 1000 miles 1 600 km or when the vehicle is lubricated check the battery condition with a hydrometer and check the electrolyte level in each cell At each SUBJECT PAR Horn I 76 Ignition Sw...

Page 123: ...g within each combustion chamber The ignition system furnishes this spark The spark must occur in each cylinder at exactly the proper time and the spark in the various cylinders must follow each other...

Page 124: ...utor 7 Voltage Regulator 8 Negative Ground Cable 9 Battery 10 Positive Cable Starting Motor 12 Starting Switch 13 Horn 14 lgnition Coil IS Ignition Switch 16 Ammeter 17 Dash Light 18 Teli Tale Light 1...

Page 125: ...Headlamp 5 Generator 6 Voltage Regulator 7 Negative Ground Cable 8 Distributor 9 lgnition Coil tO Battery 11 Starting Motor 12 Ammeter 13 Dash Light 14 Teii Tale Light 15 Fuel Gauge 16 Ignition Switch...

Page 126: ...ributor 8 Battery 9 Positive Cable 10 Voltage Regulator 11 Starting Motor 12 lgnition Coil 13 Signal Flasher 14 Starting Switch 15 Ammeter 16 Dash Light 17 Teii Tale Light 18 Fuel Gauge 19 Ignition Sw...

Page 127: ...14 0il Pressure Signal Switeh IS Temperature Sending Unit 16 8olenoid Switch 17 Foot Dimmer Switeh 18 8top Light Switeh 19 Directional Signal Flasher 2D Fuse 21 Light Switeh 22 Directional Signal Swit...

Page 128: ...rator 7 0iatributor 8 Battery 9 Positive Cable 10 Ignition Coil I I Temperature Sending Unit 12 Starting Motor 13 Voltage Regulator 14 Starting Switch IS Fuse 16 Instrument Clus ter I7 Ignition Switch...

Page 129: ...ter A Upper Beam Indicator 12 B Turn Si nal Indicator C Instrument Lights D Oil Prcuure Indicator E Charging Indicator F Temperature Gauge G Fuel Gauge H lnstrument Voltage Regulator 12 Right Tail and...

Page 130: ...Switch 13 Tcmpcrature Sending Unit 14 Startin g Motor IS Voltage Regulator 16 Fuse 17 0ircctional Signal Flasher 18 Foot Dimmer Switch 19 Stop Light Switch 20 Light Switch 21 0irectional Signal Switc...

Page 131: ...loosening the stud holding the end of the contact arm spring and slide t he end of the spring in or out as necessary Retighten the stud and recheck the pressure Too low a pressure will cause engine mi...

Page 132: ...the shaft t hey must be replaced Before installing new bearings soak them in medium grade engine oil and allow them to drain Wipe all oil from the upper part of the housing At assembly apply a film o...

Page 133: ...king Note If such cracking appears on certain plugs after fairly short service it may be caused by water leaks in the associated cylinders b At too cold a temperature plug operation in the early stage...

Page 134: ...generator depends upon the state of charge and temperature of the battery With a discharged battery the output will be high decreasing proportionally as the battery becomes charged For service inform...

Page 135: ...from the generator housing Remove the generator pulley from the armature by removing the nut and washer Do not lose the Woodruff key when the pulley is removed After this remove the drive end head as...

Page 136: ...field coils assembly in position turning front end bracket so the dowel pin in housing enters hole in end head Place commutator end plate on shaft and install long frame screws When reinstalling the...

Page 137: ...regulator is operating under varying tempera ture conditions This is accomplished through the use of a nickel iron magnetic by pass on the volt age regulator unit This shunt by passes some of the magn...

Page 138: ...stationa ry contact keeping the contacts perfectly aligned Increasing the cont act gap lowers the opening voltage Change the cont act gap by expanding or contract ing the stationary contact bracket ke...

Page 139: ...nd clean contacts per instruc tions in Par I 37 b Output does not drop shorted field circuit in the rertlllator Clean the regulator contacts and in 138 spect the regulator visually for incorrect wirin...

Page 140: ...es Fig 157 illustrates a typical starting motor the in ternal construction of which is representative of all the motors used on the models discussed here There are some differences in starting switch...

Page 141: ...Sach part of the starting motor should be removed cleaned and inspected for evidence of wear or damage The Bendix Drive should be cleaned and nspected for evidence of wear or a distorted spring Bearin...

Page 142: ...oper starting motor efficiency Soak the bearings in oil and give the bearing seats a light coating of oil 1 57 Bench Test The motor should first be checked to see that the free running voltage and cur...

Page 143: ...y reason Do not dip or wash the drive in any cleaning solution Do not remove the drive from the armature shaft Remove excess oil grease or foreign matter from the armature shaft by wiping it with a cl...

Page 144: ...nd the other lead If the unit is operating correctly the pointer will move approximately three quarter across the dial Do not attempt to repair either unit replacement is the only precedure 1 65 Indic...

Page 145: ...al 1 67 Main Light Switch Early CJ 2A The first type M odel CJ 2A switch used in produc tion through serial No 10252 is shown in Fig 161 To remove the switch from the instrument panel it is first nece...

Page 146: ...e distributor Voltage drop should not exceed 05 volt Clean and tighten connections if necessary h Connect the voltmeter from t he coil terminal on the distributor to a clean paint free spot on the dis...

Page 147: ...G LIGHT 1 Bezel 2 L ns 3 Bulb Casket 5 Housi n ond Cable 6 Scrcw 2 time and test each piug contact with the high voltage lead and with all other plug wires con nected Any sparking or meter drop indica...

Page 148: ...ned with the center line of the vehicle c Equalize all tire pressures d Rock the vehicle from side to side to equalize springs and shock absorbers e Measure the distance between vehicle head lamp cent...

Page 149: ...aiming screw counterclock wise until the beam is off Then tum the same screw clockwise until the left edge of the high 148 intensity area is 2 50 8 mm to the right of the lamp center line See Fig 171...

Page 150: ...particular vehicle as an approved production practice No attempt should be made to convert to a complete Auto Lite or Delco Remy system Auto Lite com ponents should be replaced by Auto Lite com ponen...

Page 151: ...orted Cell in Battery 0 0 0 0 Starting Motor Slow Starter Speed Discharged Battery or Shorted Cell 0 0 0 0 0 0 Ground Strap Engine to Frame Loose or Dirty Terminals Dirty Commutator 0 0 Worn Out Brush...

Page 152: ...s to Sound PROBABLE REMEDY Clean Points or Replace Adjust Clean and Lubricate Replace Adjust 020 Adjust 030 Clean Check Circuit Clean and Tighten Replace Set Timing Clean and Tighten Check Entire Circ...

Page 153: ...m Reverse Current to Open Regulated Voltage Rell ulated Current 152 I 6 volt Auto Lite 1M 100 15 100 Negative 1 260 1 225 8 219 mm J 82 221 mm J 7 178 mm J Under hood right side Auto Lite GDZ 4817 GDZ...

Page 154: ...Other Models 6 Volt Dclco Remy 1972063 Vibrator 5 9 to 6 7 6 9 to 7 4 42 to 47 Auto Lite MZ 4113 MZ 4137 MZ 4162 MCH 6207 MCH 6203 MCH 6215 Clockwise 185 rpm room temperature 005 to 030 0 127 a 0 762...

Page 155: ...amps Headlight Beam Directional Signal Charge Oil Pressure Instrument Lamp Flasher Directional Signal Fuse Data Directional Signal Heater I 154 6 Volt 5 6 3V 2 5 Auto Lite IGW 4177 1 IAD 4008 IAD 4008...

Page 156: ...the same driven plate andre lease bearing T he Auburn clutch however has three pressure springs while the Rockford clutch has six pressure springs Clutch control is through a cable near the left side...

Page 157: ...nt loosen lock nut and unscrew cable to proper adjustment then tighten locknut Free pedal travel is measured at the clutch pedal pad 10319 FIG 175 ROCKFORD CLUTCH CJ 38 CJ 5 CJ 6 156 Driven Plate and...

Page 158: ...e 19 Ciutc h Pedal 20 Serew and Lockwasher 21 D roft Pad 22 Pedol Pod and Shank 23 Rotrocting Spring 24 Pedal t o Shaft Key 25 Wnshor 26 Pedol Shaft 27 M astor C ylinder T ie Bar 28 Control Le ver 29...

Page 159: ...moved by tightening the cap and pressure nut as shown in Fig 181 the bushing will be burnished to correct size Apply a small amount of lubricant to the bushing bore J 8 Clutch Installation Auburn and...

Page 160: ...TROUBLE SHOOTING FIG 181 INSTALLING PILOT BUSHING TO FLYWHEEL Pilot Bushing lnstnlling and Burnishing Tool 2 FI whccl J 1 0 Vehicle Vibrat ions e Model DJ 3A See also Service Diagnosis in the Rear Axl...

Page 161: ...inds in Bracket Warped Pressure or Driven Plate Torn or Loose Clutch Facing Rattling Broken or Weak Return Springs in Driven Plate Worn Throw Out Bearing Fingers Improperly Adjusted Worn Driven Plate...

Page 162: ...mm j 1140 lb 517 kg 238 to 264 lb 1 6 106 94a 119 75 kg 46mm j I 1366 lb 1619 kg J T otal Plate Pressure Driven Plate Borg Beck Borg Beck Borg Beck Woven Moulded Woven Moulded Woven Moulded 8 Y 21 6 e...

Page 163: ......

Page 164: ...ase repair procedures begin with Par K 1 7 Model CJ 2A before Serial No 38221 is equipped with the same transmission with minor differences but with a remote control shift Model DJ 3A is equipped with...

Page 165: ...rance of shift dog which engages in slot of clutches and if found to be greater than 009 2286 mm clearance replace t he worn parts 164 Assemble upper clutch lever assembly in housing making sure that...

Page 166: ...separating the two units use care 4that the transmission mainshaft bearing which l bears in both housings remains in the transmission housing To separate the two units if the transfer case main drive...

Page 167: ...24 Low and Reverse Shift Fork 25 Low and Reverse Shift Rail 26 Rear Bearing 27 Main Shaft Washer 28 Ma in Shaft Nut 29 Filler Plug 30 Biocking Ring 31 F ront Countershaft Thrust Washer 32 Clutch Hub...

Page 168: ...transmission it is necessary to remove the main drive gear before the shift forks can be removed c Remove the three screws and washers attaching the front main drive gear bearing retainer to the trans...

Page 169: ...er Model CJ 3A and other models listed above a shorter spacer and two addi tional washers shown in Fig 188 were used When a transmission of the earlier type is disassembled a change to the shorter cen...

Page 170: ...mission cover screws to hold the main shaft in position Should the transmission main shaft slide out of the transmission case the synchronizer parts will fall to the bottom of the transmission case e...

Page 171: ...Bearing 27 Sp edomcter D rive Gear 28 Rear Bearing Retainer 29 Speedometer Driven Gear 30 Mnin Shaft Oil Seal 31 Tra nsmission Yoke 32 Main Shaft Washer 33 Lockwasher 34 Main Shaft Nut 35 Rcar Bearing...

Page 172: ...299 329 9 em no mark 1 30311 331 0 em etched D Should an interlock sleeve need replacing proceed as follows First drive out the taper retaining pins from the bottom of t he shift lever bosses Remove...

Page 173: ...s the front end of the main shaft through the rear bearing opening and assemble the low and reverse sliding gear on the shaft with the shifting fork groove toward the rear e Assemble the second speed...

Page 174: ...d second clutch hub and the low and second speed gear d Slide the low and second speed gear toward the rear of the transmission case e Disengage the reverse shifting arm and reverse shifting shoe fro...

Page 175: ...the mainshaft assembly from the main drive gear Be careful not to lose any of the mainshaft pilot bearing rollers m Lift the mainshaft assembly out 01 the top of the transmission case n R emove t he m...

Page 176: ...Rear Cap 8 Shims 9 Screw 10 Lockwasher 11 Bolt 12 Reor Cover 13 Gosket 14 Lock Plate 15 Tronsfer Cose 16 Shift Rod 17 Poppet Plug 18 Poppet Spring 19 Poppet Ball 20 Interlock 21 Gasket 22 Front Cap 2...

Page 177: ...the center section of the gearshift base remove the interlock pin from the cross over hole in the gearshift rod Before the gearshift rod is removed from the center section of the gear shift base plac...

Page 178: ...haft With t he tapered shoulder of the second speed gear up slide gear on the shaft far enough to hold the bearing rollers in place Remove the rubber band and slide t he gear down onto the thrust wash...

Page 179: ...al is toward the transfer case Always replace the oil seal whenever it has been removed FIG 200 INCORRECT OIL SEAL POSITION 178 FIG 20 1 CORRECT OIL SEAL POSITION K 17 T RANSFER CASE The transfer case...

Page 180: ...ch C 3281 Remove rear output shaft companion flange with brake drum if so equipped and front output shaft yoke using Tool W 172 b R emove cover bolts lockwashers and bottom cover FIG 204 BEARING CUP R...

Page 181: ...HIFT ROD OIL SEAL INSTALLER 1 Driver 2 Thimble 3 Qil Seal FIG 208 THRUST WASHER P ILOT Pilot 2 Gcor 3 Shaft See the following paragraphs for disassembly of the front and rear bearing caps K 20 Front B...

Page 182: ...211 SPEEDOMETER PINION BUSHING DRIVER t he intermediate shaft The dummy shaft should be slightly smaller in diameter than the inter mediate shaft and a little shorter than the wtdth of the intermedia...

Page 183: ...ng Retainer Transmission Main Drive Gear Oil Seal Replace Reptace K 25 TRANSFER CasE SERVICE DiaGNOSIS SYMPTOMS Slips Out of Gear High Low Shifting Lock Spring Weak Bearing Broken or Worn Shifting For...

Page 184: ...Floo CJ 2A Before Ser 38221 on Steering Post Speeds 3 F orward 1 Reverse 3 Forward 1 Reverse 4 Forward 1 Reverse Ratios First 2 798 to 1 2 605 to 1 Second 1 551 to 1 1 630 to I T hird 1 000 to 1 1 000...

Page 185: ......

Page 186: ...ints have needle bearings and are so designed that correct assembly is a very sim ple matter N o hand fitting or special tools are required L 3 Snap Ring Type Disassembly This type joint is illustrate...

Page 187: ...condition of the old gaskets M ake certain that the grease channel in each journal trunnion is open P ack the bearing cones one third full of lubricant and install the rollers Draw the Gearings into t...

Page 188: ...rm is attached to the top of the knuckle by studs and nuts and the knuckles are connected by a divided t ie rod to a steering bell SUBJECT PAR Steering Bellcrank M 1 8 Steering Knuckle Oil Seal M 16 S...

Page 189: ...eliminate the hearing spacer With this change the shims are placed between the shoulder on the pinion shaft and the bearing No difficulty will be experienced in service if the bearing spacer is used...

Page 190: ...raceway for the remaining ball SeeFig 222 10705 d 10748 1 FIG 220 RZEPPA FRONT AXLE UNIVERSAL JOINT 1 Quter Axle Shaft Snap Ring 2 0uter Shaft 3 Universal Joint Inner Race 4 Boll S CaRe 6 Axle Shaft...

Page 191: ...te that the end float of the Bendix type joint is predetermined in manufacture by the position and flange thickness of the bushing and the thrust washer shown as solid black areas in Fig 226 These par...

Page 192: ...niversal joint it is neces sary to install shims equal to the space as measured by the feeler gauge plus 015 to 050 0 381 a 1 270 mm Should no clearance be found between the driving flange and hub ins...

Page 193: ...n nut until there is a slight drag when the hub is turned Then back off ap proximately one sixth turn Install locking washer and nut tighten nut and then bendthe lock washer over the lock nut f Instal...

Page 194: ...obtain correct preload on the bear ing Shims are available in these thicknesses 003 0 076 mm 010 u 0 254 mm 005 0 1 27 mm 030 0 762 mm Install one each of the above shims at the top only Install the b...

Page 195: ...t Axle Universal Joint 16 Thruat Woaher 17 Brnke Backing Plate Screw 18 Brake Shoe nod Lining 19 Hub Oil Seal 20 Whecl Hub Bolt Nut 21 Wheel Bearing Cone ond Rollero 22 Whecl Bearing Washer 23 Whcel S...

Page 196: ...nsion plug out through the bottom When the spindle is disassembled do not lose the spacing shim between the upper face of the axle and the spindle j Remove the thrust bearing and bushings k Assemble i...

Page 197: ...ts Emergency Reset Inflate Adjust Adjust Repair or Replace Readjust Replace Readjust Readjust Replace Readjust R eadjust Readjust or R eplace Replace Readjust Replace R epair Where difficulty is exper...

Page 198: ...xlc Sho t Outer G rtose Retainer 9 Axle Shoft Bearing C one ond R oller 10 Axle Shaft Left 11 D iffcrentiRI Bc arin Cone ond Roller 12 DifTc rcntiol Shims 13 Axlt Drive G eor and Pinion FIG 233 REAR A...

Page 199: ...he vehicle with a hoist and safely support the frame ahead of the rear springs Remove the wheels and disconnect the propeller shaft at the rear universal joint companion flange D isconnect the shock a...

Page 200: ...pped with a semi floating axle Fur ther be sure that the axle shaft nut is torqued to a minimum of 150 lb ft 21 kg m Check the shaft oil seal before installing the axle shaft FIG 237 0IL SEAL DRIVER 1...

Page 201: ...o spread the carrier as the differential bearing has initial preload Use Housing Spreader T ool W 129 as shown in Fig 239 to spread the housing Clamp on a dial indicator From the side measure the carr...

Page 202: ...250 Procedure for removal is given below a Remove the hex nuts from each end of the Puller b Carefully insert the round adapter with two FIG 244 REMOVI NG P INTON SHAFT OIL SEAL flat sides through one...

Page 203: ...o install the inner pinion bearing on model 44 axle pmions use Installing Sleeve Tool C 3095 model 27 axle use Tool W 262 as shown in Fig 247 FIG 249 PULLING PINION SHAFT OUTER BEARING CUP N 9 P inion...

Page 204: ...osition for adjustment This gauge is equipped with a dial indicator which measures the distance from the finished surface on the head of the pinion to the center line of t he differential carrier bear...

Page 205: ...ion is marked minus three t he dial should indicate minus 003 Should the dial reading fail to agree with the marking on the pinion head note the difference and a corresponding amount of shims should b...

Page 206: ...n place the differen tial assembly in the carrier In the absence of tool W 129 the assembly may be installed by cocking the bearing cups slightly when the differen tial is placed in the carrier See Fi...

Page 207: ...arefully examine the surfaces of the differential case and the ring gear to make sure there are no foreign particles or burrs on the two contacting surfaces Line up the holes in the ring gear with tho...

Page 208: ...ing clips and front spring bolts may be installed Next connect the brake line hose at frame install lock clip and attach the brake line Connect the shock absorbers at the axle mounting pads Connect th...

Page 209: ...ok differentials is Jeep Powr Lok Differential Oil P art No 94557 furnished in pint cans Ordinary multipurpose gear lubricant must not be used N 19 Powr Lok Differential Overhaul The procedure for ove...

Page 210: ...e the axle shaft spacers are in place before the shaft or shafts are reinstalled h Hold each differential case half on its side and install the side gear rings with t he plates and discs assembled The...

Page 211: ...klash to the axle only make sure that the axle and yoke of the propeller shaft does not move d uring the check d If all causes of backlash mentioned above have been eliminated with the exception of th...

Page 212: ...mproperly Adjusted Adjust Adjust Replace Adjust Adjust See Differential Chatter under Trouble Shooting Powr Lok in this Section Adjust Pinion Bearings Rough Replace Pinion Bearings Loose Adjust Axle N...

Page 213: ...nion Adjustment P inion Bearing Adjustment 212 CJ 2A Before Serial No 13453 Full Floating Spicer 23 2 Thru Springs 8 21 9 em Hypoid 5 38 1 2 2 Shims 2 Shims 005 007 127 178 mm Shims DJ 3A Spicer 23 or...

Page 214: ...e Shooting 0 16 Turning Angle 0 14 gested that the following sequence be used a Equalize tire pressures and level vehicle b Inspect spindle pivot pins and wheel bearing looseness c Check wheel runout...

Page 215: ...e a torque wrench pull of 45 to 55 lb ft 6 2 a 7 6 kg m on the bolts and 30 to 40 lb ft 4 15 a 5 5 kg m on the bolts 214 Note If the steering gear to frame bolts are not properly torqued they will eve...

Page 216: ...hout causing a bind else where Always adjust within the high range through the mid position of pin traveL Do not adjust off straight ahead position Backlash in turned posi tions is not objectionable 0...

Page 217: ...ing Plug 0 6 Steering Gear Overhaul When the steering gear arm is installed on early production vehicles the line across the face of the arm and the end of the shaft should be in align ment On later p...

Page 218: ...st the ball joint screw in the plug firmly against the ball then back off one half turn and lock with a new cotter pin inserted through holes in the tube and the slot in the adjusting plug To adjust t...

Page 219: ...lf turn FIG 271 WHEEL CAMBER 0 12 Front Wheel Camber The purpose of camber Fig 271 is to more nearly place the weight of the vehicle over the tire con tact on the road to facilitate ease of steering T...

Page 220: ...ith serial numbers lower than the above should have a turning angle of not more than 23 both left and right if equipped with Bendix joints and not more than 29 if equipped with R zeppa joints On vehic...

Page 221: ...t be replaced Reassemble and lubricate the front axle and steering linkage installing new steering knuckle oil seals if present seals show any wear d On Model CJ 5 vehicles the following in spection s...

Page 222: ...r is shown in specifications at the end of this section I Check the front wheel toe in See Specifications m Check wheel toe out on turns This gives you an indication of the proper angularity of the st...

Page 223: ...3 Angle Cj 2A Cj 3A CJ 3B Cj 5 C 6 STEERING SYSTEM 0 19 STEERING SPECIFICATIONS 1 I I jeep Universal Dj 3A Ross Cam and Lever T 12 14 12 14 to I Ball Ball Bushing Ball 0005 to 002511 0 0127 a 0 0635 m...

Page 224: ...at the opposite end of the piston prevents the leakage of fluid into the rubber boot The holes in the piston head are for t he pur pose of allowing the fluid to flow from the space in back of the pis...

Page 225: ...es sure is released and the brake shoe return spring draws the shoes together pushing the wheel cylin der pistons inward and forcing the fluid out of the cylinders back into the lines toward the maste...

Page 226: ...ngs Rebuild or replace all wheel cylinders Par P 13 if one is defective as they are all probably in poor condition If the leak has allowed brake fluid to get on the linings the linings will have to be...

Page 227: ...accomplished by shortening or lengthening of the brake master cylinder eye bolt Fig 277 This is done so the primary cup will clear lhe by pass port when the piston is in the off position otherwise the...

Page 228: ...ted on the propeller shaft directly back of the transfer case On Model DJ 3A the rear brake shoes are operated through cables and conduits to form t he hand or parking brake A brake cable equalizer an...

Page 229: ...damage or wear Brake shoes may be distorted by improper lining installation and the lining should be ground true after installation on the shoes For this reason it is recommended that new or replacem...

Page 230: ...s Note On some vehicles the iining on the forward shoe is longer than the lining on the reverse shoe Install the eccentrics and the brake shoe retaining springs Should a brake drum be rough and scored...

Page 231: ...ews holdini wheel cylinder to the backing plate Remove the rubber dust covers on ends of cylin der and then the piston and piston cups and the spring See Fig 281 230 Wash the parts in clean alcohol Ex...

Page 232: ...ressure Grease or Brake F luid in Lining Shoes Improperly Adjusted Warped Brake Shoes Distorted Brake D rums Glazed or Worn Lining Restricted Brake Line Faulty Brake Cylinder Insufficient Brake Fluid...

Page 233: ...Molded Asbestos Riveted 10 219xl 75x 211 26 0 4 4 0 536 em 10 219xl 75x 211 26 0 4 4 0 536 em 6 609xl 75x 211 16 8 4 4 0 536 em 6 609xl 75x 211 16 8 4 4 0 536 cm J I 25 mm J x 19 mm 1 25 mm 61 1 165 m...

Page 234: ...xle are carried on a single tapered SUBJECT PAR Rear Wheel Bearings Q 5 Rear Wheel Bearing Adjustment Q 6 Tires Q 10 Trouble Shooting Q 11 roller bearing mounted on each axle shaft See Fig 294 These b...

Page 235: ...WHEEL DJ 3A Steering Knuckle 2 Brake 3 Hub GreAse Sui 4 lnner Bearing Cone 5 lnncr Bc a_ ring Cup 6 Hub and Drum 7 0utcr Bcorint Cup 8 0uter Beorin Cone 9 Ton ucd Woshcr 10 Nut It Cotter Pin 12 Grcnsc...

Page 236: ...ion Use a clean st iff brush to remove all particles of old lu 11 Hub and Drum 12 Shaft Key 13 0il Seal 14 N ut I 5 Co tter Pin 16 Hub Cap 17 Nut 18 Loekwasher JO Bolt bricant from bearings and hubs A...

Page 237: ...one side indicating wheels need realigning d Cuplike depressions on one side of the tread indicating wheels need balancing If the vehicle normally carries a full load two to four pounds 0 14 a 0 28 kg...

Page 238: ...ts after this treatment replace the worn parts Q 13 WHEEL BND TIRE SPECIFICaTIONS WHEELS Make Type Material Rim Size Flange Type Attachment Type Circle Dia Number Size Rear Axle Shaft End Float TIRES...

Page 239: ......

Page 240: ...which may result in a swayed or sprung frame should always be carefully checked for prop er frame alignment steering geometry and axle alignment R 2 Checking Frame AI ignment The most efficient and sa...

Page 241: ...ng or twisting of the frame is not excessive it may be straightened This should be done cold as excessive heat applied to the frame will weaken it For this reason it is recommended that badly damaged...

Page 242: ...ngt h Front Rear Modulus CJ 2A CJ 3A 12221 f 29Y l 29 1 493 in cu 311 54 em 74 3 em 74 3 em CJ 3B 0 4 Intermediate 122 f 29 2 9 1 493 in cu F ront Bumper Bar 311 54 em 74 3 em 74 3 em CJ 5 Rear K memb...

Page 243: ......

Page 244: ...rmit the axle to shift out of line Weakened springs may break causing difficulty in steering Spring attaching clips or bolts must be SUBJECT PAR Spring Removal S 4 Spring Shackles S 2 U Shackles S 6 t...

Page 245: ...21 Bushing 22 Nut 23 Co tter Pin 24 Brncket 25 Bearin g 26 Bolt 27 Nut 28 Plate and nut and tighten the nut T hen back it off two cotter pin slots and install the cotter pin The nut must be drawn up t...

Page 246: ...ate at both ends e Remove both jacks On rubber bushed shackles and pivot bolts allow the weight of the vehicle to seat the bushings in their operating positions Then torque the nuts to 27 to 30 lb ft...

Page 247: ...N ut 5 Nut a nd Lockwashcr 6 Axle Bumper 7 Bolt 8 Spring Clip 9 U Bolt 10 Grea e Retainer 11 Grcasc Seal 12 Bracket 13 Bushing 14 Spring 15 Piate a nd Sha ft 16 Lockwasher 17 Nut IS Bolt 19 Benring 20...

Page 248: ...ing usually occurs when movement takes place between the rubber bushings and the metal parts The squeaking may be eliminated by placing the bushings under greater pressure This is ac complished either...

Page 249: ...92 cm J Width 1 4 44 em 1 4 44 em 1 4 44 em Load to Attain Design Camber 450 lb 204 1 kg 735 lb 333 3 kg J 640 lb L 290 2 kg 735 lb R 333 3 kg Stack Height 648 1 645 em 1 481 3 761 em 2 090 L 5 308 e...

Page 250: ...d CJ 6 models that is identified by a stamped oval shaped bubble or SUBJECT PAR Windshield T 2 T 3 T 4 Windshield Glass T 6 T 7 Windshield Weatherstrip T 5 relief located to the right of the accelerat...

Page 251: ...eld through the loop on the hood and drawing the strap up firmly To remove the windshield from the jeep body first pull the windshield wiper vacuum hose from the windshield wiper vacuum fitting Unlatc...

Page 252: ...3A To replace the Models CJ 2A and CJ 3A wind shield glass follow the procedure outlined below a Remove screws in each side of windshield ad justing bracket at top b Bend down lip on left hand outer...

Page 253: ...es just to the rear of the front seats b Connect the stabilizer board between the top cross bow and the bracket on the windshield using the provided carriage bolts and wing nuts 252 c Install the left...

Page 254: ...icle sides and two on the wheel housing Attach the four fasteners on each side securing the top to the side rails To install the doors slide the forward welt edge into the retaining channels on the wi...

Page 255: ...After securing of the straps of the foot man loops then the top should be worked into position with the hands resulting in a smooth installation Install the side curtains with fasteners provided in t...

Page 256: ...e Section for other possible causes With some Dj 3A vehicles a drumming sound emitting from the rear of the vehicle will become audible at speeds ranging from 35 to 55 mph 56 a 88 kph This condition c...

Page 257: ......

Page 258: ...ecificat ions U 55 U 4 Power Take Off with Shaft a nd Belt Pu lley The rear power take off consists of four assemblies t he shift unit mounted on the transfer case propel ler shaft a nd universal join...

Page 259: ...shaft would be used to replace a 2 5 em shaft inter ference with the frame cross members would result U 7 Shaft Drive Assembly The standard six splined 1 34 92 mm diam eter output shaft Fig 319 is dri...

Page 260: ...he housing to filler plug level with hypoid gear oil See Lubrication Chart U 9 Governor Assembly T he Novi governor is supplied for these models This is a centrifugal type governor and is illustrated...

Page 261: ...cle D esigned primarily for use on the road a safety latch locks the hook in the closed position and two eye bolts are provided for attachment of safety c ains which should be crossed when installed t...

Page 262: ...ished with all kits f r field installation but are to be installed only on Model CJ 2A before serial number 178936 Model CJ 2A serial numbers 178936 to 215648 have these spacers installed in productio...

Page 263: ...t alignment with the crankshaft pulley Misalignment will result in ex cessive seal and bearing wear causing leakage To insure good alignment loosen the bolts which hold the pump bracket to the engine...

Page 264: ...is identified by the drawbar support straps being welded on the bottom side of the drawbar and by an additional angle iron reinforcement being welded to the drawbar center upright supports Note On Mod...

Page 265: ...d Cylinder Assy To install the main housing and cylinder assembly use the Yz 13 thread x 1 11 long bolt and Jock washer to attach the rear of the housing to the housing back support Do not tighten Ali...

Page 266: ...remove any paint and burrs from the holes in the lifting arms also remove any paint from the shoulders of the bolts and coat the shoulders with a film of light oil Start the shoulder bolts with the f...

Page 267: ...eler or tilt regulator is con veniently located at the rear of the operator s seat Rotate t he crank counterclockwise to raise the left hand plow arm or clockwise to lower it Adjust to the required am...

Page 268: ...run at idle speed b Move valve control handle backward to the lift position c Disconnect the top hydraulic line at the back of the control valve d With the implement in fully raised position and with...

Page 269: ...cesses around the ports in the pump body b Remove the two cap screws 1 4 and lock wash ers 13 securing the cover 11 to the pump body Then slide the cover carefully off the drive shaft ex tension holdi...

Page 270: ...g size to the parts removed Use fibre washers even if pump being repaired did not origin ally have them d Place a new split line seal ring 1 0 in the recess in the pump body 1 e M odel 051012 023 01 o...

Page 271: ...valve body and remove the housing rotor and two metal washers Inspect the face of the rotor carefully for any roughness If any roughness is present on the face lap the face of the rotor carefully on...

Page 272: ...eal and two in ba k of the T seal Rotate the fibre washers so that their split ends are staggered around the piston Oil the washers and T seal thoroughly with clean oil Fig 338 Replace the large and s...

Page 273: ...disconnecting the link from the lift File FIG 341 LE VELING LINK ASSEMBLY 1 Handle 2 Wdch Plu 3 Crease Fitting 4 Pinion G ear Pin 5 Pinio n G cs tr j Sh oulder Bolt 7 Sp ecial Lockwushcr S Grense Fitt...

Page 274: ...strike the end of the gear post No 10 to force it through the lock ring Remove the Welch plug No 2 by either pushing it out with the gear post or by striking it in the center with a ball peen hammer R...

Page 275: ...Shaft Front Bearing Cone Removing Ring Output Shaft Front Bearing Cone Removing Driver Output Shaft Front R ear Oil Seal Installer Puller Shift Rod Oil Seal Pilot Pin T ransfer Case Intermediate Gear...

Page 276: ...l finger tight und then tighten H turn more with wrench CHASSIS Brake Backing P late Bolts Differential Carrier Engine Front Insulator to F rame Engine R ear Insulator to Cross M ember Bolt Engine Rea...

Page 277: ...e a draw bar pull as high as 1800 pounds 817 kg may be safely used Maximum continuous draw bar pulls are most often encountered in plowing disking and har rowing and it is in these applications that t...

Page 278: ...600 1800 2000 2200 2400 9 Governor Control Posilion 1 2 3 4 5 6 7 8 9 Low 929 5 78 1675 10 43 2600 16 19 High 929 14 05 1675 25 36 2600 39 33 POWER T AKE OFF SHAFT AND VEH IC LE GROUND SPEEDS ALL GEAR...

Page 279: ...draw bar pull of zero pounds through 1200 pounds 544 kg maximum recommended in steps of 300 pounds 136 kg H P AT P T O SPLINE SHAFT Govern d Vehicle 3500 Lb Vehiele Moving with Engine peed Or3w Bar Ve...

Page 280: ...8 5 6 7 1200 4 4 8 74 20 6 17 4 15 2 13 2 10 9 8 7 1400 5 0 10 20 24 8 21 1 18 6 16 1 13 5 10 9 1600 5 8 11 65 28 9 24 6 21 8 t9 t 16 0 13 1 ISilO 6 4 t3 11 33 5 27 2 25 7 22 5 19 3 16 0 2000 7 2 14 5...

Page 281: ...les per hour No number s quare centimeter O D outside diameter ubic centimeter OS over size andle power oz ounces ubic inches P T O Power Take Off liameter Par paragraph ahrenheit psi pounds per squar...

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