manual transmission JEEP CJ 1953 Owner's Manual

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

J
flat washer, lock washer and nut.

q.
Check
the
complete
transmission for operation.

r.
Install
transmission case cover.

J-15.
T14A
TRANSMISSION
The
T14A is a three
speed
fully synchronized (all

forward
gears) transmission with helical drive gears
throughout.

The
main drive gear is supported by a
ball
bearing at the front end of the transmission case and is
piloted at its front end in an oil impregnated bush­
ing mounted in the crankshaft.

The
front end of the mainshaft is piloted in a row
of
roller
bearings set
into
the hollow end of the main

drive
gear and the
rear
end is
carried
by a
ball

bearing
mounted in the
rear
transmission case.
The
counter gear is
carried
on a single row of

rollers
at both ends. The reverse idler gear is
carried

on a single row of rollers in the center.
Thrust
is

taken
on thrust washers located
between
the
ends

of the counter and reverse idler gear and the thrust
bosses
in the case.

The
three forward gears (low, second, third) are

fully
synchronized. The synchronizer assemblies
consist of
clutch
hubs, clutch
sleeves,
clutch springs,

and
three synchronizer plates and are retained on
the mainshaft by a
select
fit snap
ring.
The
shift is manual through a cane shift lever and
interlock
assembly to the
rearward
shift fork
operating low and reverse gear and to the forward
shift fork operating second and
third
gear.
J-16.
TRANSMISSION
DISASSEMBLY
—
T14A

Refer
to Fig. J-13.

a.
If the transfer case is attached, separate it from
the transmission by removing the five capscrews
and
lockwashers.

b.
Remove cane shift housing cover and gasket

from
top of transmission case. The shift housing
cover can be disassembled if necessary, at this
point, by removing the shift
rails,
poppet
balls,

springs,
and shift forks. Refer to Fig. J-14.

c.
Remove nut and flat washer securing transfer case drive gear on the mainshaft. Remove transfer case drive gear, adapter, and spacer. Refer to

Fig.
J-15.
FIG.
J-15—TRANSFER
CASE
DRIVE

GEAR
ASSEMBLY
1—
Bearing
Adapter

2—
Bearing
Spacer

3—
Transfer
Case
Drive
Gear
4—
Flat
Washer 5— Nut
12885

FIG.
J-16—REMOVING
MAIN
DRIVE
GEAR
BEARING
1—W-329 Puller

d.
Remove main drive gear bearing retainer and
gasket. e. Remove main drive gear and mainshaft bearing snap rings.
f. Remove the main drive gear and mainshaft
bearings using bearing puller set W-329. Refer to

Figs.
J-16 and J-l7.
FIG.
J-17—REMOVING
MAINSHAFT
BEARING

1—W-329
Puller g. Remove main drive gear from transmission case.

h.
Remove mainshaft and gears as an assembly,
through the case cover opening as shown in Fig.

J-18.

i.
Remove the lockplate by tapping lightly on the
front end of the countershaft and reverse idler
shaft. Remove lockplate from
slots
in shafts. Refer
to
Fig.
J-19.

j.
Using Tool W-335, drive the countershaft
rear­

ward,
out of the case, as shown in Fig. J-20. The countershaft gear assembly
will
drop to the
bottom

of the case. Using Tool W-335
will
ensure that the

roller
bearings
will
remain in the countershaft gear
hub and may be removed as an assembly. 251

'Jeep'
UNIVERSAL SERIES
SERVICE
MANUAL

FIG.
J-23—REMOVING-INSTALLING LOW
CLUTCH
HUB
SNAP
RING 1— Mainshaft
2— Snap
Ring

3—
Snap
Ring
Groove 4—
Low
Synchronizer Assembly

J-17. DISASSEMBLY SYNCHRONIZER
ASSEMBLIES

Important:
Should a synchronizer assembly
(either low-and-reverse or second-and-high) be re­
placed for any reason on a cane shift transmission,
the shift fork that operates the synchronizer being
replaced must have an identifying letter "A" ap­ pearing just under the shaft
hole
on the side

opposite
the pin. If the letter "A"
does
not appear
on the existing fork, it must be replaced with a fork that has a letter "A" appearing thereon.
FIG.
J-24—SECOND-THIRD SYNCHRONIZER
ASSEMBLY
Refer
to Fig. J-24.

Second-Third
Synchronizer Unit.

a.
Remove springs (one on each side of unit). b.
Mark
sleeve
and hub
before
separating to en­
sure proper installation at time of assembly.
c. Remove hub from
sleeve.

d.
Remove the three synchronizer plates from third

speed
side of the hub. e.
Clean
and inspect synchronizer assembly parts.
f. Assemble synchronizer in reverse order of dis­ assembly, making certain the two synchronizer

spring
openings
are installed 120° of each other,
with spring tension
opposed.

Low
Synchronizer Unit.

Refer
tc- Fig. J-25.
The
low synchronizer assembly is serviced in the
same manner as second-third with exception of one
synchronizer spring.
12853

FIG.
J-25- -LOW SYNCHRONIZER
ASSEMBLY
1—
Synchronizer
Spring (2)
2—
Clutch
Hub

3—
Clutch
Sleeve
4— Shifter Plate
1
—Clutch
Hub
2— Shifter Plate

3—
Synchronizer
Spring (1)
4—
Clutch
Sleeve

J-18.
TRANSMISSION
CLEANING
AND
INSPECTION

Refer
to Fig. J-13.

a.
Wash transmission case inside and
outside
with cleaning solvent.
b.
Check
bearing and shaft bores. Inspect the case
for
cracks.
Check
the front and
rear
faces
and dress off any burrs with a fine
mill
file. If cracks are
found and bores are not ture, replace the case.
c.
Clean
and inspect all gears and bronze blocking
rings for
cracks,
chipped or cracked
teeth,
or ex­ cessive wear of the
teeth.

Note:
Whenever any transmission gear requires
replacement, the gear with which it
meshes
should
also be replaced.

d.
Inspect all bearings or bushings for wear or damage.
e.
Check
the second-third, and low synchronizer clutch
sleeves
making certain
they
slide freely on the clutch hub. 253

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

J J-20
TRANSMISSION
SERVICE
DIAGNOSIS

SYMPTOMS
PROBABLE
REMEDY

Lock
in Two
Gears
Replace
Poppet
or Shift Levers

Slips
Out of High Gear Transmission Misaligned with Bellhousing

End
Play in Main Drive Gear Damaged Pilot Bearing or Front Bearing.

Slips
Out of Second
Worn
Gear Replace
Weak
Poppet
Spring Replace

Noise
in Low Gear
Gear
Teeth Worn Replace Gears
Shifting
Shoe
Bent Replace
Shoe
Lack
of Lubrication Drain and Refill

Grease
Leak into Bellhousing Gasket Broken Front Bearing Retainer Replace
Transmission Main Drive Gear Oil Seal Replace Align Transmission Case to Bellhousing
and Bellhousing to Engine
Tighten Front Retainer
Replace
J-21.
TRANSMISSION
SPECIFICATIONS

HURRICANE
F4
ENGINE
3-SPEED

Vehicle:
CJ-3B,
CJ-5,
CJ-5A,

CJ-6,
CJ-6A
DJ-5,
DJ-6
Make
Type

Speeds

Ratios: —
First
Second

Third

Fourth
Warner

T90C

Synchronous Mesh
3 Forward — 1 Reverse
3.339
to 1 1.551 to 1 1.000 to 1
Warner

T96

Synchronous Mesh
3 Forward — 1 Reverse
2.605
to 1 1.630 to 1
1.000 to 1
Reverse
Interlock
Poppet
Clearance. . .
3.798
to 1

3.536
to 1
.001" to .007"

[0,025
a 0,178 mmJ

DAUNTLESS
V-6
ENGINE
3-SPEED

Vehicle:
CJ-5,
CJ-6,
CJ-5A,
CJ-6A

DJ-5,
DJ-6
Late
CJ-5, CJ-6
Make
Warner
Warner Warner

Model
AS7
T86AA

AS9
T86AA
T14A

Type..
Synchromesh
Synchromesh Synchromesh

Speeds
3 Forward — 1 Reverse 3 Forward — 1 Reverse 3 Forward — 1 Reverse
Ratios: —
First
2.798
to 1
2.798
to 1
3.100 to 1

Second
1.687 to 1 1.687 to 1 1.612 to 1

Third
1.000 to 1
1.000 to 1 1.000 to 1
Reverse
3.798
to 1
3.798
to 1 3.100 to 1 257

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

Jl
FOUR-SPEED
TRANSMISSION

Contents

SUBJECT
PAF.

GENERAL.
Jl-1

FOUR-SPEED
TRANSMISSION
REMOVAL.
Jl-2
Four-Speed Transmission
Disassembly
.
Jl-3 Four-Speed Transmission Control Housing
Disassembly
Jl-4
Four-Speed Transmission Reassembly Jl-5
SUBJECT
PAR.
Four-Speed Transmission Control Housing
Reasse mbly Jl-6

Transfer
Case Adapter Plate Oil Seal .
.
Jl-8
Four-Speed Transmission Installation Jl-7

FOUR-SPEED
TRANSMISSION
SPECIFICATIONS.
.
.
Jl-10

SERVICE
DIAGNOSIS
Jl-9 10771

FIG.
Jl-1—FOUR-SPEED
TRANSMISSION

1—
Control
Housing Gasket
2—
Control
Housing Assembly
3— Mainshaft Assembly
4—
Thrust
Washer
5—
Thrust
Washer
6— Reverse Shifting
Shoe
7— Reverse Shifting Arm
8—
C-Washer

9— Reverse Shifting Arm Pivot
10—
O-Ring

11— Reverse Idler
Gear
Assembly
12— Snap Ring
13—
Thrust
Washer
14—
Sleeve

15— Bearing Rollers
16— Spacer
17— Reverse Idler
Gear

18— Pipe Plug
19— Countershaft Gears 20— Bearing Rollers
21— Spacer 22— Spacer
23—
Thrust
Washer

2
4
—Bellhousi ng-to-Transmission Adapter Plate
25— Bearing Retainer
26— Bearing Retainer Bolt
27— Bearing Retainer Lockwasher
28— Bearing Retainer Gasket
29—
Main
Drive
Gear

30— Bearing Rollers 31— Transmission Case
32— Adapter Plate Lockwasher
33— Adapter Plate Capscrew
34— Side Opening Cover Gasket
35— Side Opening Cover Bolt
36— Side Opening Cover Lockwasher
37— Side Opening Cover 38— Countershaft
39— Shifting Arm Pivot Taper Pin
40— Bearing
41— Snap Ring
42—
Oil
Seal 43— Spacer
44— Reverse-Idler
Gear
Shaft 45—
Lock
Plate
46—
Lock
Plate Lockwasher
47—
Lock
Plate Bolt
48— Gasket
49— Adapter Plate 50— Adapter Plate Lockwasher
51— Adapter Plate Bolt
52— Cotter Key
53— Nut 54— Washer
55— Gasket 259

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

Jl

1—
Blocking
Rir

2—
Direct
and 1

3—
Snap
Ring

4—
Spring

5—
Shifting
Plat

6—
Direct
and 1 7—
Third
Speed
J1-3
4-Speed Transmission Disassembly

•
Refer to Fig. Jl-1.

Note;
The
models
T-98 and T-18 four-speed
transmission are similar in design with exception of
the second
speed
gear-to-mainshaft arrangement.
In
the model T-18 transmission, the second
speed

gear is a slide fit on the mainshaft, whereas in the
model T-98 transmission roller bearings and a
spacer are required in this area. Refer to Figs. Jl-3
and
Jl-4.

a.
Remove the transmission to transfer case adapter plate and gasket. Remove the oil seal from
the plate and, if damaged, discard the seal.
b. Remove the transmission control housing as­
sembly. Refer to paragraph Jl-4 for its dis­
assembly.
c. To make certain the two blocking rings, direct-

and-third
clutch hub, and direct-and-third clutch
sleeve
will
be assembled in their original relation­

ship,
mark them with a quick drying lacquer or an
electric pencil. Also mark the blocking ring, low-
and-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
from the reverse idler gear. Remove
the arm from the reverse shifting arm pivot.
f. Move the low-and-second
speed
gear
into
neutral position.
g. Remove the bearing retainer and gasket.
Remove the snap rings from the main drive gear
and
the outer race of the ball bearing.

h.
With a bearing puller, remove the main drive
gear ball bearing. 1436S
i
Hub

Gear

izer
Assembly

ironizer
Assembly
i.
Remove the oil slinger.

j.
Remove the snap ring from the outer bearing
race
of the transmission mainshaft ball bearing.
k. With a bearing puller, remove the mainshaft

ball
bearing.

Note:
It may be necessary to drive the mainshaft

rearward
by striking the end of the main drive gear with a lead hammer to get sufficient clearance
to install the bearing puller plates.

I.
Slide the direct-and-third clutch
sleeve
to the

rear
(third
speed)
position. Separate 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 of the top
of the transmission case.

n.
Remove the main drive gear from the trans­
mission case.
o. Remove the mainshaft bearing rollers from the gear.
p.
Mark
relationship
between
synchronizer hubs

and
the splines on the mainshaft.
q. Begin disassembly of the main shaft assembly by removing the snap ring which holds the direct

and
third synchronizer assembly on the mainshaft,

r.
Remove the front blocking ring from the front
of the shaft.
s. Slide the direct-and-third-synchronizer assembly

and
the third-speed-gear assembly off the main-shaft.
t. Remove the snap ring at the rear of the main-
shaft. Slide the second synchronizer assembly and the blocking ring off the mainshaft.

FIG.
Jl-4—T-18
FOUR-SPEED TRANSMISSION MAINSHAFT ASSEMBLY
ng 8—Snap
Ring
15—Ball

third
Clutch
Sleeve
9—Thrust
Washer 16—Low and Second
Clutch
10—
Second
Speed
Gear
17—Retaining
Ring

11—
Mainshaft
18—Low and Second Speed
te 12—Blocking
Ring
19—Second Speed
Synchroni

rhird
Clutch
Hub 13—Shifting Plate 20—Direct and
Third
Synch

Gear
Assembly 14—Poppet
Spring
261

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

Jl
necessity for assembly, one should be made at this
time to assist on disassembly. One can be made by
using a \Y%N [2,86 cm.] diameter steel rod cut to

9.850*
{25,02
cm.] long.
Break
sharp
edges
with a
mill
file.) Keep the dummy shaft in contact with
the countershaft at all times to prevent dropping
the bearing rollers or thrust washers,

z.
With
the dummy shaft in position, place the
transmission
case on its side and carefully
roll
the countershaft gear cluster out of the case,

aa.
Complete the disassembly by removing the dummy shaft, thrust washers, four
sets
of bearing
rollers,
and spacers.

bb.
To disassemble the reverse idler gear assembly,
remove one of the snap rings and tap out the

washers,
both
sets
of bearing rollers, center spacer,
and
sleeve.
Remove the remaining snap
ring.

J1-4.
4-Speed
Transmission
Control
Housing
Disassembly

•
Refer to Fig. Jl-5.

The
gearshift lever, spring, and spring seat were previously removed for removal of the transmission

from
the vehicle.

a.
Remove the lock pins from the gearshift forks

and
gearshift rod ends. Remove the expansion plugs
from
the front and
rear
of the gearshift lever base. Remove back-up light switch.

b.
Remove the center (third and high) gearshift

rod
first. Drive this gearshift rod out the
rear

of the gearshift lever base. As the gearshift rod is
withdrawn
from 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, place a finger over the
hole
to prevent

loss
of the
ball
and spring.
Then
remove the rod.

c»
Remove the low- and second-speed gearshift rod
in
the same manner.

d.
Remove the gearshift rod lock balls and springs

and.
with a piece of
wire,
push the two gearshift rod
interlock
plungers out of the pockets in the center
section of the gearshift base.

In
the reverse gearshift rod end is a spring-loaded
plunger which prevents the
driver
from accidentally
shifting into reverse gear. Should this part require
servicing,
proceed as follows:
Remove the cotter key from the rod end assembly

and
at the same time hold a finger over the
hole

to prevent
loss
of the spring.
Then
shake out the
spring
and
ball.
Compress the plunger and spring

until
the C-washer
groove
just clears the end of
the casting. Remove the C-washer.

J1-5.
4-speed
Transmission Reassembly •
Refer to Fig. Jl-1.
Assemble the unit in the reverse order of dis­
assembly noting the following points:

a.
Assemble the countershaft assembly with the
fabricated
dummy shaft. The bronze front thrust

washer
and the steel backed bronze
rear
thrust
washer
should be coated with stiff lubricant and
installed
with the lugs
engaged
in the notches

in
the end of the gear cluster. Place the assembly
in
the transmission case and install the counter­
shaft from the
rear,
keeping the countershaft and
dummy shaft in contact to prevent dropping

bearing
rollers or washers. Tap the countershaft
lightly into position in the front of the case but
do not seat it until the reverse idler gear assembly

and
shaft have been installed in the case.

b.
Install
the reverse idler gear shaft in the case

until
the lock plate slot is adjacent to the slot in
the countershaft. Insert the lock plate in the
slots

of the shafts making sure the plate ends are square

with
the slots.
Install
the lock plate screw and
lockwasher
to act as a pilot while tapping the
shafts alternately into position in the case. Tighten
the lock plate screw securely.

c.
Begin assembly of the second speed synchronizer assembly (see
Fig.
Jl-6) by installing the low-and
-

second-speed clutch hub in the low-and-second-
speed gear.
Install
the retaining ring in the speed gear.
Install
the retaining ring in the low and
FIG.
Jl
-6—ASSEMBLING
SECOND-SPEED

SYNCHRONIZER
1—
Low
and Second
Clutch
Gear

2—
Ball

3—
Low
and Second
Clutch
Hub
4—
Shifting
Plate
second speed gear. Slide the hub out of the gear

in
the direction
opposite
the shift fork
groove

until
the
holes
in the hub are clear of the gear.
Install
the shifter plates and springs. Push the
hub back into the gear until the springs touch the

internal
teeth
of the gear. Push one of the shifter
plates toward the center of the gear while installing

ball.
See
Fig.
Jl-6 .
This
will
hold the
ball
in position.
Install
the other two balls in the same manner.

Be
careful when rotating the assembly to prevent the hub from slipping out of the gear. When the

balls
are installed, push the hub into the gear

until
the balls snap into the neutral position.

d.
Assemble the
direct
-
and
-
third
synchronizer as­
sembly in accordance with the instructions given

in
Section J, Par.
J-lle.

e.
Start
assembly of the mainshaft assembly by 263

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

Jl

FIG.
Jl-9—INCORRECT
OIL
SEAL POSITION J1-7.
Installing
4-Speed
Transmission

Install
the four-speed transmission in the reverse

order
of the removal, noting the following points:

When
installing the front adapter plate (Fig. Jl-1,

insert
the bearing retainer in the adapter plate and
position the adapter plate against the flywheel
housing.
With
the adapter plate cap screws tight, make sure the bearing retainer can be removed
freely. If not, relocate the adapter plate and tighten
again to
test
proper location of adapter plate.
When
installing
rear
adapter plate, be sure cap
screw heads do not protrude beyond the adapter
plate face or interfere with transfer case fitting
tightly against
rear
adapter plate.

When
installing transfer case gear on the trans-
FIG.
Jl-10—CORRECT
OIL
SEAL POSITION

mission
rear
splined drive shaft tighten the large
gear nut securely and insert cotter pin.
Sink
cotter

pin
well into nut
slots
so it
will
clear
P.T.O.
drive.

J1-8.
Adapter Plate
Oil
Seal
It
is important that the four-speed transmission
adapter plate oil seal be correctly installed to
prevent flow of lubricant from the transfer case
to the transmission. Should the lubricant level be
low in the transfer case and high in the transmission,
check the position of the oil seal. See Fig. Jl-9 and

Jl-10.
Correctly
positioned, the lip of the oil seal is
toward
the transfer case. Always replace the oil

seal
whenever it has been removed. 265

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

ft
TRANSFER CASE

Contents

SUBJECT
PAR.

GENERAL
. . .K-1

TRANSFER CASE REMOVAL
K-2
TRANSFER CASE DISASSEMBLY
K-3
Front
Bearing Cap K-4

Rear
Bearing Cap K-5

TRANSFER CASE REASSEMBLY.
. .K-6

TRANSFER CASE INSTALLATION
K-7
TRANSFER CASE LINKAGE
ADJUSTMENT
K-8

SERVICE
DIAGNOSIS
K-9

SPECIFICATIONS
.K-10

K-1. GENERAL
All
4-wheel-drive models are equipped with a
transfer
case to connect the power to the front
axle.
It is essentially a
two-speed
transmission
located at the
rear
of the standard transmission
and
provides a low and direct gear.

The
transfer case gears are controlled by the
driver

through
one shift lever.
Early
'Jeep'
Universal
Models with the F4-134
Hurricane
engine
are equipped with two transfer case shift control levers.

a.
On vehicles equipped with one transfer case

shift
lever, the transfer case shift lever has four
positions: 2WD
High,
4WD
High,
Neutral, and
4WD
low. The forward position of the lever 2WD

High
allows the
rear
wheels only to drive. The

first
rear
position (4WD High)
engages
the 4- wheel drive and provides high range 4-wheel drive.

The
second
rear
position (Neutral)
disengages
all power to the wheels and is used for stationary
power take-off operations. The last
rear
position
(4WD
Low) provides low range 4-wheel drive.

b.
On vehicles equipped with two transfer case

shift
levers, the transfer case front axle drive lever (left hand lever)
gives
a choice of 2-wheel or 4-
wheel drive. In the forward (out) position the
vehicle is in 2-wheel drive. Move the lever to the

rear
(in) position for 4-wheel drive operation.
The
4-wheel-drive
auxiliary-range
shift lever (right

hand
lever) has three positions; low, neutral, and
high.
The forward position (low)
gives
low-range
4-wheel drive. The center position (neutral) dis­
engages
all power to the wheels and is used for

stationary
power take-off operations. A built-in in­

terlock
prevents shifting into low range, 2-wheel
drive.
This
feature protects the
rear
axle from over­

load.
K-2.
Removal of
Transfer
Case

The
transfer case may be removed from the vehicle
without removing the transmission. Where both

transmission
and transfer case are to be removed
together,
refer to Section J. To remove only the

transfer
case from the vehicle, proceed as follows:

a.
Drain
transmission
and transfer case and replace

drain
plugs.

b.
Disconnect the brake cable.

c.
Disconnect front and
rear
propeller shafts at
the transfer case. See "Propeller Shafts and
Uni­
versal
Joints."

d.
Disconnect
speedometer
cable at transfer case. e. Disconnect the transfer case shift levers. On
vehicles equipped with two shift levers
loosen

set screw and remove pivot pin. Use a screw
driver

to pry shift lever springs away from shift levers.
Lift
levers from transfer case. On models equipped

with
a single shift lever remove pivot pin cotter

key,
and the adjusting rod attaching nut to remove

shift
lever. See Fig. K-4.
f. Remove cover plate on
rear
face of transfer case.

Remove
cotter key, nut and washer from trans­

mission
main shaft.
g. If possible, at this point remove the transfer case main drive gear from the transmission main

shaft.
If not possible, see
step
j below.

h.
Remove transfer case torque reaction support

bracket
bolt and nut.

i.
Remove transmission to transfer case bolts.
j.
Remove transfer case. If the transfer case main

drive
gear has not been removed in
step
g above,
proceed as follows:
Brace
the end of the trans­

mission
main shaft so that it cannot
move
in the
transmission,
pull
the transfer case to the
rear
to 267

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

K
ment, the shaft should have .004" to .008"
[0,102

a
0,203
mm.] end play. Adjustment is made by
selective
shim installation
between
the cap and the
case. Shims .003", .010" and .031" [0,076,
0,254,

0,787
mm.] in thickness are available for this ad­
justment. Do not install the rear cap oil seal until
the bearings are correctly adjusted. Both the front
and
rear oil seals may be installed with oil seal

driver
Tool W-143, shown in Fig. K-12.

When
installing the end yokes on the output shafts,
inspect for the presence of
felt
seals in each oil
seal guard. (The oil seal guard is a part of each
yoke assembly.) Felt seals should be installed in the oil seal guards if
they
are not present. When
installing the shift
rail
oil seals in the front bear­
ing cap, it is necessary to protect the seals against
damage when passing over the shift
rail
notches.
Protect them with the thimble, and install them with the driver, Tool W-130, shown in Fig. K-9.

K-7.
Transfer Case Installation

The
installation of the assembly in the vehicle is
the reverse of the removal operation covered in
Par.
K-2.

If
the transmission was removed from the vehicle,
lubricate the pilot bearing and also lubricate the
transmission and transfer case as outlined in the

"Lubrication
Section". Be sure that the clutch pedal has %"
[19,05
mm.] free travel as outlined

in
the
"Clutch
Section".

K-8.
Transfer Case Linkage Adjustment

Adjust
the link to provide
xh"
[12,7 mm.] clear­
ance
between
the floor pan and the shift lever
bend when operating in four wheel drive low
position. Refer to Fig. K-4.

K-3.
TRENSFER
CESE
SERVICE
DIAGNOSIS

SYMPTOMS PROBABLE REMEDY

Slips
Out of
Gear (High-Low)
Shifting
Lock
Spring Weak Replace Spring

Bearing
Broken or Worn Replace
Shifting
Fork
Bent Replace

Slips
Out of
Front Wheel Drive
Shifting
Lock
Spring Weak. Replace

Bearing
Worn or Broken Replace

End
Play in Shaft. . . ..... Adjust Shifting
Fork
Bent.. Replace

Hard Shifting
Lack
of
Lubricant
Drain
and
Refill

Shift
Lever
Stuck on Shaft Remove, Clean and Lubricate
Shifting
Lock
Ball
Scored Replace
Ball

Shifting
Fork
Bent Replace
Fork

Low
Tire
Pressure Inflate

Grease Leak
at
Front
or
Rear Drive
Grease
Leak
at Covers. Install New Gaskets

Grease
Leak
between
Transmission and Transfer Cases Install New Gaskets

Grease
Leak
at Output Shaft Install New Oil Seal

K-10.
TRANSFER
CESE
SPECIFICATIONS

Transfer
Case:
All
Models

Spicer

18

On
Floor

Gear
Ratio: 1.00 to 1
2.46 to 1 273

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

N
scribed
in
Pars.
N-ll through N-l9 for standard
axles, with the exception of the following torque
recommendations. Torque the differential case
bearing
cap screws 70 to 90 lb-ft. [9,7 a 12,4 kg-m.]

and
the cover screws 15 to 25 lb-ft. [2,1 a 3,4
kg-m.].
The ring gear screws on axles with Powr-

Lok
differentials should be torqued as follows:

Model
30 and 44 axles 35 to 55 lb-ft. [4,84 a 7,60 kg-m.].

N-24. TRAC-LOK DIFFERENTIAL
As
optional equipment
Trac-Lok
Model 44 differen­
tial
is available on all Jeep Universal vehicles equipped with semi-float flanged axle shafts.
A
conventional differential transmits all of the
ring
gear torque through the differential gears to the axle shafts. Torque is at all
times
equal on the axle shafts, and if one wheel slips, the other wheel

can
only put out as much torque as the slipping
wheel.

The
Trac-Lok
differential is similar,
except
that

part
of the torque from the ring gear is trans­ mitted through clutch packs
between
the side gears

and
differential case. The multiple disc clutches

with
radial
grooves
on the plates and concentric
grooves
on the discs are
engaged
by a preload

from
Belleville springs, plus separating forces from
the side gears as torque is applied through the
ring
gear.

The
Trac-Lok
construction permits differential action when required for turning corners and trans­mits equal torque to both
wheels
when driving

straight
ahead. However, when one wheel tries to spin due to leaving the ground, a patch of ice,
etc., the clutch packs automatically provide more
torque to the wheel which is not trying to spin.
It
can be
seen
then that the
Trac-Lok
differential
resists wheel spin on bumpy roads and provides
more pulling power when one wheel tries to slip.
In
many cases of differences in traction, pulling
power
will
be automatically provided until both
wheels
start to slip.

In
diagnosis of vehicle operators' complaints, it
is important to recognize two things:

a.
If, with unequal traction, both
wheels
slip, the

Trac-Lok
has
done
all it can possibly do.

b.
In extreme cases of differences in traction, the
wheel with least traction may spin after the
Trac-

Lok
has transferred as much torque as possible
to the non-slipping wheel.
N-25.
Lubrication

The
Trac-Lok
differential requires a special
lubri­

cant
and ordinary multipurpose gear lubricants

MUST
NOT be used. Use only 'Jeep* Differential
Oil,
Part
No. 94557.

Trac-Lok
differential may be cleaned only by disassembling the unit and wiping with clean rags. Do not flush the
Trac-Lok
unit.

Note:
The
Trac-Lok
differential is serviced at the
same time intervals as the standard differential.
N-26.
Trouble
Symptoms

If
noises
or roughness, such as chatter, are present
in
turning corners, the probable cause is incorrect

or
contaminated lubricant.
Before any differential is removed and disassem­
bled for chatter complaints, the correctness of
lubri­

cant
can and should be determined.

A
complete
lubricant
drain,
and
refill
with specified

Limited
Slip Differential lubricant
will
usually
correct
chatter.

The
following procedure is recommended to ensure

complete
removal of old lubricant.

a.
Warm
the lubricant by vehicle road operation,

or
5 minutes of operation in gear at 30 mph with
both
wheels
off the ground on a hoist.

Caution:
Never place the transmission in gear with
the
engine
running when only one wheel of a

Limited
Slip Differential equipped vehicle is raised.
The
vehicle might drive itself off the
jack
and produce damage or
injury.

b.
Drain
lubricant while
warm.
Remove
drain
plug

or
cover to
drain
completely. If cover is removed,

it
may be necessary to replace gasket at this time.

c.
Refill
axle with specified
Limited
Slip Differen­

tial
lubricant.

d.
Operate the vehicle for approximately ten miles
[16,09
km.], making at least ten figure 8 turns
to flush the old lubricant out of the clutch packs.

e.
Repeat
steps
b, c, and d, making sure to replace
the cover gasket if required in
step
c.
f. It is possible that slight chatter, requiring ad­
ditional
vehicle operation, may remain after
step
e. If chatter persists after 100 miles
[160,9
km.]
of vehicle operation, or remains severe after
step

e above, disassembly and repair
will
be necessary.
N-27.
Unit
Inoperative

Proper
performance and capabilities of
Limited
Slip
Differentials are
often
misunderstood. No
precise
methods
of measuring
Limited
Slip Dif­

ferential
performance are generally available in the field. A functioning unit can be determined by
relatively
simple vehicle operational
tests,
as
follows:

a.
Place one wheel on
good
dry pavement, and the
other on ice, mud, grease, etc.

b.
Gradually
increase
engine
rpm to obtain maxi­

mum
traction
prior
to "break-a-way." The ability
to
move
the vehicle
effectively
will
demonstrate

proper
performance.

c.
If extremely slick surfaces, such as ice or grease,

are
used
some
question may exist as to proper per­
formance at
step
b. In
these
extreme cases a prop­

erly
performing
Limited
Slip Differential
will
pro­
vide greater "pulling" power by lightly applying
the parking brake.

N-23.
Trac-Lok
Differential Disassembly
and
Reassembly

It
is recommended that the
complete
axle assembly
be removed from the vehicle, when it
becomes
necessary to remove the
Trac-Lok
from the hous­

ing.
Refer to Par. N-3 and N-12 for removal of axle shafts and differential case from axle housing. 303