tow JEEP CJ 1953 Owner's Guide

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

J
control
levers and remove arms. Remove the shift
levers and then remove the
sleeve,
poppet
balls,

spring,
and interlock pin.
Check
the oil seal care­
fully
for oil leakage and replace if necessary,
b.
If it is evident that a minimum clearance of .001" to .007" [0,025 a 0,178 mm.] cannot be
obtained
between
the end of the interlock
sleeve
and
the shift levers, even though the
longest
sleeve

has been installed, replace the existing
sleeve
with

an
Interlock Sleeve Service Kit.
When
assembling the interlock
sleeve
be sure that
the shift lever
poppet
spring works freely inside the

interlock
sleeve
and that the interlock pin is not
omitted from inside the spring.
If
the notched surfaces of the shifting lever are

dirty
or rough, they should be cleaned and
smoothed. If notched surfaces are scored or dam­
aged, the lever should be replaced.

Each
time an interlock
sleeve
or shift lever is
replaced,
check the clearance
between
the inter­

lock
sleeve
and the shift lever.
J-10.
Transmission
Inspection

a.
Wash the transmission case thoroughly 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

or
the bores are not true, replace the case.

c.
Clean
and inspect all gears and bronze blocking
rings for
cracks,
chipped or cracked teeth, or ex­cessive wear of the teeth.

d.
Inspect all bushings and bearings for wear or damage.
e.
Check
first and reverse sliding gear for freedom of movement on the mainshaft.

f.
Check
the clutch
sleeve
to see that it slides freely on the hub.

g.
Check
the condition of the bearing retainer oil

seal.

J-11.
Transmission
Reassembly
—
T90,
T86AA

•
Refer to Fig. J-5, J-7
Assemble the unit in the reverse order of disas­
sembly, noting the following points:

a.
Oil circulation is provided
between
the trans­ mission and transfer case by the addition of drilled
passages
between
the two units. The
rear
face of
the transmission case is drilled with two %" 11,11 mm],
holes
and two [6,35 mm.] holes.

The
front face of the transfer case is drilled with
two %"
[11,11
mm.]
holes
to register with
those

drilled
in the transmission case. When making re­
placement of either unit or case, it is important that
mating parts be installed, that is, if a transmission
case is drilled use a drilled transfer case. It is im­
portant that the correct gasket, having
openings
for
oil
passage, be used with the drilled cases.

b.
Position the reverse idler gear in the case and

install
the shaft using care that the slot at the shaft end is correctly aligned to receive the lock plate.
c. Assemble the spacer, six washers, and four countershaft
needle
bearings in the countershaft
gear hub, using special tool W-166 with loading

sleeve,
as shown in Fig. J-9 and J-10. Place the

spacer
inside the hub and insert the special tool in
the spacer. Place a washer at each end of the spacer

and
load a set of bearing rollers at each end.
Then

add
a washer, a set of bearing rollers, and finally
another washer at each end to complete the as­ sembly. Place the countershaft gear assembly in
the case but do not install the countershaft until
the mainshaft and main drive gear are installed.

d.
When assembling the mainshaft gears, the low

and
reverse sliding gear is installed with the shift
shoe
groove
toward the front of the transmission.
e. The sequence of assembly of the synchronizer

unit
is shown in Fig. J-4.
First
install the two springs in the high and intermediate clutch hub

with
the spring tension opposed. Place the right lipped end of one spring in a slot of the hub and
place the spring in the hub.
Turn
the hub around
and
make exactly the same installation with the other spring, starting with the same slot. In­

stall
the three synchronizer shifting plates in the
three
slots
in the hub with the smooth side of the
plates out. Hold the plates in position and slip the second and direct speed clutch
sleeve
over the hub

with
the long beveled
edge
toward the long part
of the clutch hub.
Install
the two blocking rings
one on each side of the hub.
Install
the completed
assembly on the mainshaft with the beveled
edge

of the clutch
sleeve
toward the front end of the
shaft.

f.
Install
main drive gear bearing
onto
the main
drive
gear shaft, using tool
KF-128A.

g.
When installing the mainshaft, use care that the
needle
bearing rollers in the main drive gear
are
correctly positioned. Use heavy grease to hold
them in position for assembly.

h.
The countershaft gear set, when assembled in
the case, should have .012" to .018" [0,305 a
0,457
mm.] end play.
This
clearance is obtained by selective thickness of the
rear
steel thrust washer

which
is available in .0555" and .0625"
[1,410
a 1,587 mm.] thickness.

After
installation of the front and
rear
bearing

retainers
on the mainshaft,
turn
the transmission over to allow the gears to mesh and also to permit alignment and installation of the countershaft.

i.
To install the countershaft gear set in the
case, first install the large bronze thrust washer
at the front of the case with the lip of the washer
entered in the slot of the case. Use heavy grease to hold this washer in position. Next, install the steel thrust washer at the
rear
of the case.
Start

the countershaft into the case just enough to hold
this washer in place. Align the slot in the counter­ shaft with the slot in the reverse idler gear shaft
to permit installation of the lock plate. Be sure the

thrust
washers are correctly positioned.
Then

position the bronze-faced washer against the
rear
end of the gear and place the gear in its running
position.
Tap
the countershaft through the counter­shaft gear set and the case, forcing out the special
tool W-166.

j.
Attach the transfer case to the transmission 247

J

THREE-SPEED
TRANSMISSION
before
the unit is installed in the vehicle. When
doing this, use care that the countershaft and

reverse
idler shaft lock plate shown in Fig. J-8
is correctly positioned in the recess in the transfer case housing.
Three
\
Y%"
long [2,86 cm.] screws and
two 1" long [2,54 cm.] screws are used to attach the

transfer
case housing to the transmission housing.
Install
the 1" long [2,54 cm.] screws in the lower

left
and lower right mounting holes.
FIG.
J-12—SYNCHRONIZER
SPRINGS

J-12.
Transmission — T96

•
Model DJ-5, DJ-6

a.
Remove the shift housing and gasket from the top of the transmission case if it has not
been
pre­ viously removed. The shift housing can be disas­
sembled, if necessary, at this point by removing the
shift
rails
and forks from the shift housing. Use

care
and do not
lose
the
poppet
balls and springs.

b.
Drain
the lubricant from housing and wash
the assembly with a suitable solvent.

c.
Remove the screws from the front main bearing

retainer
and remove retainer.
d.
Remove nut which attaches the companion

flange
to the main shaft; also the flat washer and

lock
washer.

e.
Remove the companion
flange
with special puller

tool
W-172.
f. Remove the screws attaching the
rear
bearing

retainer
to case and remove retainer and gasket.
g. Remove oil seal
speedometer
drive gear and
main
shaft
rear
bearing from the bearing retainer.

h.
Remove the reverse idler and countershaft

lock
plate.

i.
Using
tool
W-193 or a
soft
drift, drive the
countershaft out through the
rear
of the case allow­
ing the counterhsaft gears to drop to the
bottom

of the case.

j.
Remove the main drive gear with bearing
through the front of the case.
Note
that this gear cannot be removed when the countershaft gears are
in
position.
Take
care when removing this gear not
to misplace the thirteen
needle
type
rollers in the
gear end of the shaft which make up the main shaft
pilot bearing.

k.
Remove the main shaft snap
ring,
the main
shaft bearing snap ring and the mainshaft bearing

which
is grooved, from the main shaft.
I.
Remove the bronze blocking ring then remove
the clutch hub and synchronizer assembly through
the top.

m.
Remove the low and reverse sliding gears and
the constant mesh gear and main shaft in one unit,
through the top.

n.
Remove the countershaft gears through the
top.
Take
care not to misplace the twenty rollers at each end of the long spacer as well as the two

thrust
washers and the two roller spacer bearings,

o.
Using a
soft
drift, drive the reverse idler shaft
out toward the
rear
and remove the gear.

J-13.
Transmission Cleaning and Inspection
Refer
to Fig. J-7.

a.
Wash the 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 or the bores are not true, 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 bushings and bearings for wear or damage.

e.
Check
low-and-reverse sliding gear for freedom
of
movement
on the main shaft.
f.
Check
the intermediate-and-high clutch
sleeve
to see that it slides freely on the intermediate-and-
high clutch hub.
J-14. Transmission Reassembly
—-
T96
a.
Position the reverse idler gear in the case and
install
the shaft using care that the
slot
at the shaft
end is correctly aligned to receive the lock plate.

b.
To assemble the countershaft gear, it is neces­

sary
to use Tool W-193 or equivalent
Fig. J-9.
Place
the special
tool
through the gear set and insert the
long spacer positioning it at the center of the gear
set. Place a set of twenty rollers at each end of the

spacer
followed by a spacing washer at each end.

A
small amount of grease
will
hold the spacing

washer
in position. Place the assembled counter­ shaft gear set in the
bottom
of the case with the
large gear toward the front.

C*
Install
the
rear
main shaft bearing on the main shaft with the closed side of the bearing toward
the front or low end of the shaft. Replace the bear­
ing snap ring and main shaft snap
ring,

d.
Pass the front end of the main shaft through the
rear
bearing opening and assemble the low and 248

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

reverse sliding gear on the shaft with the shifting

fork
groove
toward the rear.
e. Assemble the
second
speed
gear on the shaft
with the
teeth
which
engage
in the clutch
sleeve

toward the front of the case.
f.
Next,
assemble
the synchronizer unit. The as­ sembly
sequence
of the synchronizer is shown in

Fig.
J-12.
First
install the two springs in the high
and intermediate clutch hub. These springs must
be installed with the spring
tension
opposed.
Place the right lipped end of a spring in a
slot
of the
hub and place the spring in the hub.
Turn
the hub
around and make exactly the same installation
with the other spring starting with the same
slot.
Fig.
J-5. Install the three synchronized shifting

plates
in the three
slots
in the hub with the
smooth

side
of the
plates
out. Hold the
plates
in
position

and slip the
second
and direct
speed
clutch
sleeve
over the hub. Install the two blocking rings one
one each
side
of the hub.
g. Place
some
heavy
grease
in the main shaft
pilot and
position
the thirteen
needle
type
roller bearings.

h.
Install the main drive gear. If the bearing has

been
removed,
note
that the closed
side
is assembled
toward the inside of the case.

i.
Enter
the main shaft bearing in the case and

assemble
the shaft in position.

j.
Install the front bearing retainer. k. For
ease
in installing the countershaft, turn the
transmission case over to allow the gears to mesh.

With
the countershaft thrust washers correctly
positioned,
start the countershaft through the rear
of the case with the lock plate
slot
toward the rear
and the
slot
in alignment with the
slot
in the
12879

FIG.
J-13—T14A
THREE-SPEED
TRANSMISSION

1—
Retainer
Screws
2—
Main
Drive
Gear
Bearing Retainer
3—
Retainer
Gasket
4—
Oil
Seal 5— Snap Ring (small)
6— Snap Ring (large) 7—
Main
Drive
Gear
Bearing
8—
Oil
Retaining Washer (slinger)
9—
Main
Drive
Gear

10— Mainshaft Pilot Bearing Rollers
11—
Case

12— Nut
13—
Flatwasher

14— Spacer 15—
Bearing
Adapter
16— Snap Ring

17—
Mainshaft Bearing
18— Reverse
Gear

19— Snap Ring
20—
Low
Synchronizer Assembly 21— Synchronizer Blocking Ring 22—
Low
Gear

23— Mainshaft
24— Second
Gear

25— Synchronizer Blocking Ring
26—
Second-Third
Synchronizer Assembly
27— Synchronizer Blocking Ring
28— Snap Ring 29— Countershaft Front Thrust Washer (large)
30— Countershaft
Gear

31— Reverse Idler
Gear
Bearing Washer
32— Reverse Idler
Gear
Roller Bearings 33— Reverse Idler
Gear
34— Countershaft
Rear
Thrust Washer (small)
35— Countershaft Bearing Spacer Washer* 36— Reverse Idler Shaft
37— Countershaft Roller Bearings
38— Spacer Washer
39— Countershaft
40—
Lockplate

249

THREE-SPEED
TRANSMISSION

14271

FIG.
J-14—-CANE
SHIFT
CONTROL
HOUSING
ASSEMBLY

1—
Shift
Lever
Knob
2—
Shift
Lever

3—
Control
Housing
4—
Plug
5—
Shift
Rail
(Second-Third) 6—
Shift
Rail
Cap 7—
Interlock
Plunger
8—
Shift
Rail
(Low-Reverse)
9—
Shift
Lever
Fulcrum
Ball

10—
-Pin

11—
Shift
Lever
Support Spring
12—
Shift
Fork
13— Poppet
Ball

14— Poppet Spring
15—
Gasket

16—
Lockwasher
17—Bolt reverse idler gear shaft. Press the shaft through
the gears and
into
the front of the case, forcing out Tool W-193.

I.
Locate the lock plate in the
slots
of the reverse

idler
gear shaft and countershaft. Tap the two
shafts until lock plate is
tight
against case, m. Install rear bearing snap ring and rear main-
shaft bearing on shaft.
n.
Attach rear bearing retainer and gasket to the
transmission case. Tighten cap screws evenly and
securely.

Install
speedometer
drive gear on shaft with

o.

the shoulder of gear toward the front. Check
the oil seal which is installed next and replace with
new one if necessary.

p.
Install the companion coupling
flange
with the 250

J

THREE-SPEED TRANSMISSION
J-19.
TRANSMISSION
REASSEMBLY
—

T14A

Note; Lubricate all internal transmission
parts

before
assembly
using the proper lubricant.
a. Position
reverse
idler
gear
with
Arbor
Tool

W-336,
roller bearings, and thrust
washers
in the
case.
Install
reverse
idler shaft forcing out
Tool

W-336.
Make certain the slot end of the idler shaft
is correctly aligned to receive the lockplate. Refer
to Fig. J-19.
FIG.
J-26—COUNTERSHAFT GEAR
BEARING ARBOR
1—
Roller
Bearings 2— Spacer
3—
Arbor
Tool W-335
b.
Assemble the
countergear
center
spacer,
four
bearing
spacers,
and countershaft bearing rollers

in
the countershaft
gear
hub
assembly
as
follows,
using Arbor
Tool
W-335.
Place
the
center
spacer

inside the hub and insert Arbor
Tool
in the
spacer.

Place
a bearing
spacer
at
each
end of the
center
spacer
and load a set of bearing rollers, and
place

a bearing
spacer
at
each
end to complete the as­
sembly. Refer to Fig. J-26 and J-27.

c.
Install large
countergear
thrust
washer
in the

front
of the
case.
Position small thrust
washer
on
the countershaft
gear
hub
with
lip facing groove in
the
case.
Holding the countershaft
gear
assembly
in
position, start the countershaft in the
rear
of the

case
with
the lockplate slot toward the
rear
and the
slot in alignment
with
the slot in the
reverse
idler
FIG.
J-27—COUNTERSHAFT BEARINGS
AND SPACERS INSTALLED
1— Countershaft
Gear
2— Countershaft Bearing Rollera
3— Countershaft

4—
Spacers
5
—Center Spacer
FIG.
J-28—LOCKPLATE INSTALLATION
1— Reverse Idler Shaft 2—
Lockplate

3— Countershaft
gear
shaft.
Press
shaft through the
gear
hub as­
sembly and into the front of the
case
forcing out

Tool
W-335.

d.
Locate the lockplate in the slots of the
reverse

idler
shaft and countershaft. Tap the two
shafts
alternately
until
lockplate is tight
against
case.

Refer to Fig. J-28.
e. When assembling the mainshaft,
first
install mainshaft low
gear
and bronze blocking
ring.
In­

stall
the low synchronizer
assembly,
then install
the
select
fit
snap
ring.
Refer to Fig. J-23.
Note; Mainshaft
snap
rings are
select
fit to
eli­

minate clutch hub and main drive
gear
bearing
end play. Make certain correct
snap
ring
is installed at
assembly.

f.
Install the mainshaft
second
gear
and bronze

blocking
ring.
Install the second-third synchronizer
assemblv,
then install
select
fit
snap
ring.
See
Fig.
J-22.

g.
Install
reverse
gear
on mainshaft.

h.
Install the mainshaft and
gear
assembly
as a

unit,
through the top cover opening of the trans­
mission
case.
Refer to Fig. J-18.

i.
Install bronze blocking
ring
onto the
second-

third
synchronizer
assembly.

j.
Install main drive
gear
roller
bearings
using low
melting
point
grease
to hold them in place. Refer
to Fig. J-29.
k. Install the main drive
gear
and oil retainer

washer
(slinger) into the
case
with
the cutaway
portion
of the
gear
positioned downward toward
the
countergear
assembly.
Guide main drive
gear
onto the mainshaft using
care
not to drop the roller bearings, as shown in Fig. J-30. 254

'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

Jl

FOUR-SPEED
TRANSMISSION
U.
On the T-98 transmission remove the snap rings
holding the thrust washer, bearing rollers, second-

speed
gear, and spacer on the mainshaft. Slide
these
components
off the shaft. Refer to Fig. Jl-3.

Note:
The second
speed
gear in the T-18 trans­
mission is a slide fit
onto
the mainshaft and
does
not contain roller bearings or a spacer.
v. If the synchronizer assemblies are to be dis­
assembled and serviced proceed as follows:
Wrap

the
second-speed
synchronizer assembly in a cloth
to prevent losing the lock balls and springs. Push the clutch hub out of the low-and-second-speed
gear in a direction
opposite
the shift fork
groove.
Remove the cloth.
Lift
the balls, springs, and
plates out of the hub.
w. Remove the lockplate for the countershaft and
reverse idler gear shaft.

x.
Use a pry bar in the
slot
of the reverse idler gear
shaft to
loosen
the shaft.
Then,
slip the reverse

idler
gear shaft out of the housing and gear.
Lift
the reverse idler gear assembly from the transmission case.
y. To remove the countershaft, use a heavy brass
drift
and drive the countershaft toward the
rear
of
the transmission case. When the countershaft end
is just about even with the inside of the trans­ mission case, use a dummy shaft to force it the
remainder of the way. (Since a dummy shaft is a
FIG.
Jl -5—FOUR-SPEED TRANSMISSION CONTROL PARTS

1—
Shift
Lever

2—
Control
Housing Pin

3—
Shift
Handle
4—
Control
Housing Cap 5—
Washer

6—
Control
Lever
Spring
7—
Breather
Assembly
8— Reverse Shift
Rail

9—
Shift
Rail
Interlock Plunger

10—Expansion
Plug 11—
Low
and Second Shift
Rail

12—
Shift
Rail
Interlock Pin
13—
Direct
and
Third
Shift
Rail

14—
Control
Housing
15—
Shift
Rail
Poppet Spring
16—
Shift
Rail
Poppet
Ball

17—
Lockwire
18—
Low
and Second Shift
Fork
19—
Lock
Pin
20—
Shift
Rail
End 21—
Direct
and
Third
Shift
Fork

22— Reverse Plunger
23— Reverse Plunger Spring
24— Reverse
Rail
End
25—
Cotter
Pin
26— Reverse Plunger Poppet Spring
27— Reverse Plunger Poppet
Ball
28—
C-Washer
262

'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

M
If
the joint binds when assembled, tap the yoke
lightly to relieve any pressure on the bearings at the end of the
journal.

M-8-
Steering
Knuckle
Service

The
steering knuckle pins pivot on tapered roller
bearings. Replacement of
these
bearings requires

removal
of the hub and brake drum assembly,
wheel bearings, axle shaft, spindle, steering tie rod,

and
steering knuckle. Disassemble the steering
knuckle
as follows:
Remove the
eight
screws which hold the oil seal

retainer
in place. Remove the four screws holding
the lower pivot pin bearing cap. Remove the four screws holding the upper bearing cap in place. Re­
move
the bearing cap. The steering knuckle can
now be removed from the axle. Wash all parts in cleaning solvent. Replace any damaged or worn

parts.
Inspect the bearing and races for scores,
cracks,
or chips. Should the bearing cups be damaged,
they
may be removed and installed with

Special
Driver
W-138, as shown in Fig. M-9.
M-9.
Reassemble
and
Bearing Preload

Reverse
the procedure of Par. M-8 to reassemble
the unit. When reinstalling the steering knuckle, sufficient shims must be installed under the top

bearing
cap to obtain correct preload on the bear­
ing.
Shims are available in
these
thicknesses: .003"
[0,076
mm.] .010"
[0,254
mm.] 005"
[0,127
mm.] .030"
[0,762
mm.]

Install
one each of the
above
shims at the top only.
Install
the bearing caps, lockwashers, and screws,

and
tighten securely.
Check
the preload on the bearings by hooking a

spring
scale, Tool C-690, in the
hole
in the knuckle

arm
for the tie rod socket.
Take
the scale reading when the knuckle has just started its
sweep.

The
kingpin bearing preload should be 12 to 16 lb. [5,43 a 7,24 kg.] with the oil seal removed. Remove

or
add shims to obtain a preload within
these
limits.
FIG.
M-9—SPINDLE
PIN
BEARING
CUP
DRIVER

1—Tool
W-138
FIG.
M-10—TURNING
ANGLE
STOP
SCREW

1—Stop
Screw
M-10.
Replacing Steering
Knuckle
Oil Seal
Remove the old steering knuckle oil seal by remov­ ing the
eight
screws which hold it in place.
Earlier

production vehicles are equipped with seals con­ sisting of two oil seal halves.
Later
production vehicles are equipped with oil seal assemblies con­
sisting of a split oil seal and backing ring assembly,

an
oil seal felt, and two seal retainer plate halves.

Examine
the spherical surface of the axle for scores or scratches which could damage the seal.
Smooth any roughness with emery cloth. Before installing the oil seal felt, make a diagonal
cut across the top side of the
felt
so that it may be
slipped over the axle.
Install
the oil seal assembly

in
the
sequence
given above, making sure the

backing
ring (of the oil seal and backing ring as­
sembly) is toward the wheel.

After
driving in wet, freezing weather swing the
front
wheels
from right to
left
to remove moisture

adhering
to the oil seal and the spherical surface of
the axle housing.
This
will
prevent freezing with

resulting
damage to the seals. Should the vehicle be
stored for any period of time, coat
these
surfaces

with
light grease to prevent rusting.

M-11.
AXLE
SHAFT
INSTALLATION

Refer
to Fig. M-2.

Installation
of the front right and
left
axle shaft
is the same and is given in the following
paragraphs.

a.
Clean
all parts of
dirt
and foreign matter.

b.
Enter
universal joint and axle shaft assembly

in
the axle housing, taking care not to knock out
the inner oil seal.
Enter
the splined end of the
axle shaft
into
the differential and push
into
place. 281