brakes JEEP CJ 1953 Service Manual

1953-71

SERVICE MANUAL

JeeP
UNIVERSAL
4-WHEEL DRIVE
CJ-3B CJ-5A
CJ-5
CJ-6
CJ-6A
2-WHEEL DRIVE DJ-5
DJ-6

Copyright®
1977

FI Jeep Corporation Corporate Publications
Printed
in USA
Reprinted
6-77

SM-1046
SECTION
INDEX

NAME
Section

General
Data
A

Lubrication
B

Tune-Up
C

Hurricane
F4 Engine
D

Dauntless V-6 Engine
Dl

Fuel
System
E

Exhaust
System
F

Exhaust
Emission Control System F4 Engine
Fl

Exhaust
Emission Control System V6-225 Engine
F2

Cooling System
G

Electrical
H

Clutch
I

3-Speed
Transmission
J

4-Speed
Transmission
Jl

Transfer
Case
K

Propeller Shafts
L

Front
Axle
M

Rear
Axle
N

Steering 0

Brakes
P

Wheels 0

Frame
R

Springs
Shock Absorbers
S

Body
T

Miscellaneous
U

'Jeep*
UNIVERSAL SERIES
SERVICE
MANUAL

B
LUBRICATION
AND
PERIODIC SERVICES

Contents
PAR. SUBJECT
PAR.
SUBJECT

GENERAL
.B-l
Chassis
Lubrication
B-7
Engine
Lubrication System B-4, B-6

Special
Lubricants B-2

Fresh
Lubricant.
.B-3

LUBRICATION CHARTS
. Pages 8, 9

SERVICE
MAINTENANCE SCHEDULE.
.B-8
Air
Cleaner
B-2
5,
B-2
6
Air
Filter
—
F.E.E.C.
System Canister
B-2
4

Axle
U-Bolts B-49 Body
Lube
Points: B-65 Hood Hinge Pivot Points B-66

Glove
Compartment Door
Latch
B-6
7
Tailgate Hinges .B-68

Brakes,
Adjust .B-41
Brake
Linings .B-42

Brake
Master Cylinder B-40
Charging
Circuit
B-l9
Clutch
. B-43, B-44
Cooling System—Radiator. B-28, B-29 Differentials
........
.B-50, B-51, B-52, B-53

Distributor
B-14, B-l5

Engine
Oil B-9
Engine
Oil
Filter
B-10, B-ll

Engine
Tune-Up B-20
Exhaust
Emission Control System
B-2
2

Exhaust
Manifold Heat Control Valve. . . .B-l2

Exhaust
System
B-2 3
Fan
Belt . .B-21
Front
Axle U-Joint B-54, B-55

Generator
.B-16
Headlights B-61
Heater Controls B-62
Lights
and Controls B-59 Positive Crankcase Ventilation Valve. . . .B-l3
Shock Absorbers B-48
Spark
Plugs. B-17
Speedometer Cable. .B-60

Spring
Bushings.. . .B-46

Spring
Shackles .B-47
Steering
Gear
B-2 7
B-l. GENERAL
All
'Jeep' Universal vehicles require periodic
lubri­

cation and other maintenance services for normal
vehicle
usage
and application to promote satis­ factory operation and prevent
excessive
wear. Un­
der severe operating or atmospheric conditions
these
services should be performed more
often
than
under normal conditions. It should also be remem­
bered that common short trips and
stop-and-go
driving
are more severe on lubrication
points
than
Starting
Circuit
B-l8

Tie
Rod and Drag
Link
Sockets
.
B-45

Tires
B-64

Transmission
and Transfer Case—
Lubricant
Level
Check B-30

General
B-31

Transfer
Case B-32
Transmission
.B-33

Transmission
and Transfer
Case
—

Lubricant
Change .B-34
General
.B-35

Transfer
Case B-36
Transmission
B-3
7, B-38

Transfer
Case Linkage B-39

Universal
Joints and Slip Joints.
.......
.B-58

Wheel
Bearings..
.........
. . .B-56, B-57
Windshield
Wiper and Washer B-63

LUBRICATION
OF

OPTIONAL EQUIPMENT
B-69
Centrifugal
Governor. .B-71
Pintle Hook .B-70

Powr-Lok
or
Trac-Lok
Differential B-72

PARTS REQUIRING
NO LUBRICATION.
. . .B-73

Alternator
Bearings. B-76
Clutch
Release Bearings.
.............
.B-74
Shock Absorbers B-78
Springs
B-7
7
Starter
Motor Bearings B-75

Water
Pump Bearings B-74

LUBRICATION REQUIREMENTS FOR OFF-HIGHWAY OPERATIONS
B-79

Air
Cleaner B-82

Chassis
Lubrication
B-83

Engine
Oil B-80
Engine
Oil
Filter
B-81
Differentials .B-86
Front
Axle U-Joints. B-84
Transfer
Case and Transmission .B-85
constant
speed
driving on highways, and even more
intensified in extreme cold or hot weather; there­ fore, vehicles driven under
these
conditions must
be lubricated and serviced more
often
than nor­ mally operated vehicles. The specifications of
types
and
amounts of lubricant given in the Lubrication

Chart
and
text
of this section should be closely
followed. The off-highway operation lubrication
notes,
given in the last part of the section, should
be followed when applicable. 7

B
LUBRICATION B-3.
SERVICE
MAINTENANCE
SCHEDULE

Perform
the following operations at the mileage shown. Two thousand miles equals
3,200
km.

SERVICE
MAINTENANCE
SCHEDULE

OPERATION
VEHICLE
^ n>
MILEAGE
IN
THOUSANDS

6 8 10 12 24 30
Check Wheel Nut Torque*
Check
Fluid
Level
in Battery X Check
Fluid
Level
in Brake Master Cylinder0. X
Service
Cooling
System X Service Tires X

Lubricate
Distributor
Cam Lubricator (F4-134) X
Lubricate
Steering Linkage X

Lubricate
Propeller Shaft Universal Joints X

Lubricate
Propeller Shaft
Slip
Joints ; X
Lubricate
Tie Rod and Drag
Link
Sockets................................... X Change Engine
Oil
and
Filter,
and Service Air Cleaner (F4 134 Engine)** X
Change Engine Oil and
Filter,
and Service Air Cleaner (V6-225 Engine)**....
Check Brake Operation and Pedal
Free
Play X Check
Clutch
Pedal
Free
Play. .... X
Check all
V-Belt
Tensions X
Check Exhaust Emission System
(If
so equipped)*** \ X
Service Positive
Crankcase
Vent
Valve
and Breather . .' X
Road Test
Including
a Check of all Instrument
Lights
and Controls X Tune-up Engine
Check Operation of
Manifold
Heat
Control
Valve

Clean
Exterior of Radiator

Align
Headlights • Check Brake
Linings
,
Check Exhaust System for Leaks Replace Canister Air
Filter
(F. E. E. C. System)
Check
Axle
U-Bolt
Torque. Check Lubricaunt
Level
of Front
Axle
Universal Joints
Check Shock Absorber Mountings and Bushings Check Front and
Rear
Spring Bushings

Lubricate
Distributor
(V6-225).
Replace Spark, Plugs
Check Charging and Starting Circuits
Lubricate
Tailgate Latch, Supports and Hinges.

Lubricate
Door and
Hood
Hinge Pivots ;
Lubricate
Glove Compartment Door Latch

Lubricate
Heater Controls •

Lubricate
Windshield
Wiper and Washer Controls
Clean,
Repack and
Adjust
Wheel Bearings
Change Transmission and Transfer Lubricant. .
Replace
Dry-Type
Air Cleaner • Check Lubricant
Level
of
Differential

Lubricate
Transfer
Case
Shift
LeArer
Control
C«se.
. , . . . . . . . .
Continuing
each
2,000 miles

Continuing
each
6,000 miles

Continuing
each
24,000 miles

X
Continuing
each
30,000 miles
•Check after the
first
200 miles [320
km.
J
of operation.
If
wheel or wheels are changed for any
reason,
have
wheel nut torque rechecked after an additional two hundred miles of operation
••Service mileage shown or every 60 days, whichever occurs
first.

•••Maintenance check on emission system must be performed per
information
in this manual. "See text for brakes.

"Nj
^Miles
2,000
6,000
12,000
18,000
24,000
30,000
Kilometers

3,200
9,600
19,200
28,800
38,400 48,000

B-9.
Engine Oil

For
maximum
engine
protection under all driving conditions encountered during the recommended

oil
change intervals, it is necessary to use only

"MS"
certified
sequence-tested
oils. The term
"MS"
must appear on the oil container singly or

in
conjunction with other designations. "MS" des­
ignated oils are heavy-duty detergent oils that are
formulated to withstand all service conditions in
modern powerplants. Engine oils designated only
as
"ML"
and/or
"MM"
are not recommended and should not be used except in an emergency when

"MS"
oil is not available. Certified
sequence-tested

engine
oils are described on their containers by

such
phrases as:
meets,
exceeds,
excels, or has
proven superior in the
test
requirements,
test
sequences, MS Service
tests,
standards, and service

requirements,
of automotive manufacturers, auto­
makers,
or car manufacturers for MS service or
Service
MS.
It
may be necessary to change
engine
oil more
frequently than normally recommended, depending upon the type and quality of oil used, the severity
of operation conditions, if the
engine
is used for
short
periods in cold weather, or if the
engine
is allowed to idle for excessive periods.

Always
drain
the crankcase while the
engine
is hot since
dirt
and contaminants are then more
likely
to be held in suspension and therefore
will

drain
out more completely.
Drain
the crankcase as follows:

a.
Position the
drain
receptacle under the
drain

plug.

b.
Remove the
drain
plug using the correct size

wrench.
Be careful of hot oil.
c.
Carefully
clean the
drain
plug. Inspect and

replace
the gasket, if deteriorated.
d.
When the oil has drained, replace and tighten
the crankcase
drain
plug. 12

B

LUBRICATION
Note:
Hard
shifting of the transmission gear in
cold weather is a positive indication that the
lubri­

cant
is of the wrong viscosity or of poor quality

which
allows it to congeal.

B-38.
Optional
4-Speed
Transmission
and
Transfer Case

The
four-speed transmission and transfer case re­

quire
separate lubrication for each unit as
they
have no cross-over oil passage. At each transmission
service check, the
fill
plugs of
both
four-speed

transmission
and transfer case should be pulled
and
the lubricant refilled to level if necessary.

B-39.
Transfer
Case
Linkage

The
transfer case shift linkage should be lubricated

periodically.
All
bearing surfaces that are assembled
with
studs and cotter pins should be disassembled, cleaned, and coated with a
good
waterproof grease.

The
bearing surfaces that cannot be disassembled
should be lubricated with a lubricant that
will
penetrate the bearing
area.
These bearings include
the two on the cross shaft assembly and the
threaded stud.

The
type
of penetrating lubricant recommended is
DuPont
"PM 7", No. 2911, or its equivalent.

B-40.
Brake Master Cylinder

Clean
the top of the
fill
cap and also the housing

area
around it. Remove the cap and observe the
fluid
level. It should be
half
an inch
below
the top
of the fill-hole. If not, add brake fluid to
half
inch
[1,3 cm.]
below
the top of the fill-hole. Use
only heavy-duty brake fluid conforming to speci­
fication
SAE-J-1703.
Be sure to handle the brake

fluid
in clean dispensers and containers that
will
not introduce even the
slightest
amount of other

liquids
or foreign particles. Replace and tighten
the
fill
cap.

B-41.
Adjust Brakes

Refer
to Section P.
B-42.
Brake Linings

Refer
to Section P.

B-43.
Adjust Clutch

Refer
to Section I.

B-44.
Clutch Cross Shaft (Lever Type)

Lubricate
the clutch cross shaft in accordance with
specifications given in the
Lubrication
chart: see
Item
1. Chassis Bearings.

B-45.
Tie Rod and Drag
Link
Sockets

The
tie rod and drag
link
sockets
are equipped

with
lubrication
fittings
and should be lubricated

per
specifications given in the
Lubrication
chart: see Item 1. Chassis Bearings.
B-46.
Front
and
Rear Spring
Bushings

The
condition of the spring bushings is indicated
by the alignment of the spring pivot and spring
shackle
bolts.
Check
the alignment of
these
bolts,

and
check that nuts are
tightened
securely.

B-47.
Spring
Shackles

Rubber
bushings are provided on the spring
shackles.
These rubber bushings have no lubrication
fitting and it is very important that
they
never be lubricated.

B-48.
Shock Absorbers

Visually
check for broken mounts or bolts, worn

or
missing bushings on the shock absorbers. Refer
to Section S.

B-49.
Front and
Rear
Axle
U-Bolts

Torque
the front and
rear
axle U-bolts. Refer to Section S.

B-50. Front
and
Rear
Axle
Differentials
—
Lubricant Levels

The
lubricant
level of all front and
rear
differentials should be at the level of the fill-hole.

B-51.
Front and
Rear
Axle
Differentials
—
Changing
Lubricant
B-52.
Conventional Differentials

To
remove the lubricant from the front or
rear
differential,
it is necessary to remove the housing cover. Let the lubricant
drain
out, and then flush
the differential with a flushing oil or light
engine

oil
to clean out the housing
(except
Powr-Lok
or
Trac-Lok
Differentials). Do not use water, steam,
kerosene, or
gasoline
for flushing.

Reinstall
the housing cover, replacing the gasket whenever necessary, torquing the cover
bolts
to 15 to 25 lb-ft. [2,1 a 3,4 kg-m.].
Remove the filler plug, and
refill
the differential
housing as specified in the
Lubrication
Specifica­
tions.

B-53.
Powr-Lok
or
Trac-Lok Differential

Some vehicles may be equipped with the
Powr-Lok

or
Trac-Lok
Differential as optional equipment.
Special
lubricant and ordinary multipurpose gear

lubricants
must
not be used. Use only
'Jeep*
Differ­

ential
Oil,
Part
No. 94557.

Powr-Lok
or
Trac-Lok
differentials may be cleaned
only by disassembling the unit and wiping with
clean
rags. Do not flush the unit. Refer to Sec­
tion N.

B-54.
Front Axle Universal Joint
—
Lube

Check
the level of the front axle universal joint
lubricant
at each front wheel by removing the
fill-hole plug. The lubricant should be level with
the fill-hole. If required, add lubricant as specified

in
Lubrication
Specifications.

B-55.
Front
Axle
Universal
Joint
— Service

On
all 4-wheel drive vehicles the front axle
uni­

versal
joint should be serviced by removing the shaft and thoroughly cleaning the universal joints

and
housing. For the correct procedures, refer to
Section M. 16

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

B
Reinstall
the axle shafts, and
refill
the housings to
plug level using the universal joint lubricant
specified in
Lubrication
Specifications.

B-56.
Front
Axle Wheel Bearings

To
lubricate the wheel bearings, it is necessary
to remove, clean, repack, and adjust them. When
front wheel hubs and bearings are removed for
lubrication,
they should be thoroughly washed in a
suitable cleaning solvent. The bearings should be
carefully
dried and then given a thorough cleaning

and
inspection. Use a clean brush to remove all

particles
of old lubricant from bearings and hubs.

After
the bearings are cleaned, inspect them for
pitted races and rollers. Also, check the hub oil
seals.

Note:
Wheel bearing lithium base lubricants are
used at the factory for
initial
fill
of
these
bearings.
When
lithium base and sodium base lubricants are

mixed,
the result is a thinned-out mixture that
can
bleed through seals. It is therefore important
that lubricants with the correct base be used when

lubricating
the wheel bearings.
Should
leaks occur at wheel bearing seals, the leaks

may
be caused by a mixture of two
types
of
lubri­

cants.
In such cases, the old lubricant should be
completely removed before new lubricant is added.

Wheel
bearings should be thoroughly cleaned,
lubricated
with lithium base and reinstalled.

Repack
the bearing
cones
and rollers with grease

and
reassemble hub in the reverse order of the
disassembly. Test the bearing adjustment as out­

lined
in Section Q.

B-57.
Rear
Axle Wheel Bearings

The
Rear
wheel bearings an early models equipped

with
lubrication fittings with a vent opening
through the housings above each fitting should be
lubricated
sparingly, each
2,000
miles
[3.200
km.].

Use
a hand compressor and wheel bearing grease,
forcing
the grease through each lubrication fitting

until
it flows from the vent. Vent should be kept
clear
of obstruction or grease
will
back up into the

brakes.
Do not add grease after it flows from the
vent for it may be forced through the wheel key-
way
onto
the outside of the wheel and possibly

onto
the brake linings.
Rear
wheel bearings that do
not have lubrication fittings should be removed
each
12,000
miles
[19.200
km.] and the bearing
cleaned, inspected and repacked. Refer to proce­

dure
in Par. B-56.

Note:
When servicing the Flanged Axle Unit
Bear­

ing Assembly, refer to Section N, Par. N-5 for

proper
lubrication procedures.

B-58.
Propeller Shafts
and
Universal Joints

The
propeller shaft slip joints and universals should
be lubricated with a hand compressor grease gun so as to not damage the bearing seals. The units
should be lubricated with a
good
quality grease.

Refer
to the
Lubrication
Chart
for lubrication fre­
quency and lubricant type and grade. B-59.
Lights
and
Controls

a.
Check
all interior and exterior lights and light
switches for proper operation, including: parking
lights, headlamps (high beam and low beam),

tail
lights, brake lights, directional lights, and in­ strument panel lights.

b.
Check
all instrument panel controls and
instru­

ments for proper operation.

B-60.
Speedometer Cable

Remove the
speedometer
cable from its housing every
12,000
miles
[19.300
km.].
Clean
it thor­
oughly and coat it with a
good
quality light graphite grease.

B-61.
Headlights

Refer
to Section H.

B-62.
Heater Controls

Apply
Lubriplate
130-A to all friction points and
pivot points on the heater controls panel unit as well as the pivot points at the dashpot. Apply

a
few drops of penetrating oil all along the Bowden
cable.
This
oil
will
penetrate into the center wire.

B-63.
Windshield Wiper and
Washer Controls

Lubricate
the friction points and the pivot points
on the windshield wiper transmission and linkage

arms
with a slight amount of
Lubriplate
130-A.

B-64.
Rotate Tires

Refer
to Section Q for the correct method of rotat­ ing the tires.

B-65.
Body Lube Points
•
Refer to Par. B-66 through B-68.

B-66.
Hood Hinge Pivot Points

Lubricate
the frictional points of the hood hinge
pivot points with a few drops of light-weight
engine

oil.
B-67.
Glove Compartment Door Latch
Sparingly
wipe
Lubriplate
130-A on the
glove
com­
partment door latch.

B-68.
Tailgate Hinges

Lubricate
the friction points of the tailgate hinges

with
a few drops of light-weight
engine
oil.

B-69.
LUBRICATION
OF
OPTIONAL EQUIPMENT

B-70.
Pintle Hook

When
lubricating the vehicle, place a few drops of oil on the pintle hook and safety latch pivot pins.

B-7!.
Centrifugal Governor

Check
the oil level in the governor housing at each
vehicle lubrication. Use the same seasonal grade
oil
as is used in the
engine
and change oil at each

engine
oil change. Do not
fill
the housing above
the level indicating plug opening. Keep the vent

in
the filler plug open at all times. 17

TUNE-UP

C-29.
SERVICE
DIAGNOSIS

POOR
FUEL ECONOMY Ignition Timing Slow or Spark Advance Stuck

Carburetor
Float High
Accelerator Pump Not Properly Adjusted High Fuel Pump Pressure

Fuel
Leakage

Leaky
Fuel Pump Diaphragm Loose Engine Mounting Causing High Fuel Level in Carburetor

Low
Compression
Valves Sticking
Spark
Plugs Bad

Spark
Plug Cables Bad
Weak
Coil
or Condenser Improper Valve Tappet Clearance

Carburetor
Air Cleaner Dirty
High Oil Level in Air Cleaner Dragging Brakes

Front
Wheels Out of Alignment

Tires
Improperly Inflated Inaccurate Odometer

Faulty
Fuel Tank Cap
Clogged
Muffler or Bent Exhaust Pipe Sticking Exhaust Manifold Valve

LACK
OF POWER
Low
Compression Ignition System (Timing Late)
Improper Functioning Carburetor
or Fuel Pump

Fuel
Lines
Clogged

Air
Cleaner Restricted Engine Temperature High Improper Tappet Clearance
Sticking Valves
Valve Timing Late

Leaky
Gaskets
Muffler
Clogged

Bent Exhaust Pipe Sticking Exhaust Manifold Valve —
Dauntless V-6 Engine

LOW
COMPRESSION
Leaky
Valves Poor Piston Ring Seal Sticking Valves
Valve Spring Weak or Broken
Cylinder
Scored or Worn
Tappet Clearance Incorrect Piston Clearance too Large

Leaky
Cylinder Head Gasket

BURNED
VALVES AND SEATS Sticking Valves or too Loose in Guides
Improper Timing
Excessive Carbon Around Valve Head and Seat Overheating
Valve Spring Weak or Broken
Valve Tappet Sticking
Valve Tappet Clearance Incorrect
Clogged
Exhaust System

Defective
Valve
Lifter
— Hydraulic
VALVES
STICKING
Warped Valve Improper Tappet Clearance Carbonized or Scored Valve
Stems

Insufficient Clearance Valve Stem to Guide
Weak or Broken Valve Spring Valve Spring Cocked Contaminated Oil

OVERHEATING
Inoperative Cooling System
Theromstat Inoperative Improper Ignition Timing
Improper Valve Timing
Excessive Carbon Accumulation
Fan
Belt too Loose

Clogged
Muffler or Bent Exhaust Pipe
Oil
System Failure Scored or Leaky Piston Rings
Sticking Exhaust Manifold Valve — Dauntless V-6 Engine

POPPING-SPITTING-DETONATION
Improper Ignition Improper Carburetion
Excessive Carbon
Deposit
in
Combustion Chambers
Poor Valve Seating Sticking Valves
Broken Valve Spring Tappets Adjusted too Close
Spark
Plug Electrodes Burned
Water or Dirt in Fuel
Clogged
Lines Improper Valve Timing

Clogged
Fuel Filter Sticking Exhaust Manifold Valve —
Dauntless V-6 Engine

EXCESSIVE
OIL CONSUMPTION Piston Rings Stuck in Grooves, Worn or Broken Piston Rings Improperly Fitted or Weak Piston Ring Oil Return
Holes
Clogged

Excessive Clearance, Main and
Connecting Rod Bearings

Oil
Leaks at Gaskets or Oil Seals
Excessive Clearance, Valve Stem
to Valve Guide (Intake)

Cylinder
Bores Scored, Out-of-
Round or Tapered
Too Much Clearance, Piston to Cylinder Bore
Misaligned Connecting Rods
High Road
Speeds
or Temperature
Crankcase
Ventilator Not Operating

BEARING
FAILURE
Crankshaft
Bearing Journal Out-of-Round

Crankshaft
Bearing Journal Rough

Lack
of Oil
Oil
Leakage

Dirty
Oil

Low
Oil Pressure or Oil Pump Failure

Drilled
Passages
in Crankcase or Crankshaft
Clogged

Oil
Screen Dirty
Connecting Rod Bent 34

D

HURRICANE
F4
ENGINE
D-112.
SERVICE
DIAGNOSIS

Poor
Fuel
Economy Ignition Timing Slow or Spark Advance Stuck

Carburetor
Float High
Accelerator Pump Not Properly Adjusted
High
Fuel
Pump Pressure

Fuel
Leakage
Leaky
Fuel
Pump Diaphragm
Loose Engine Mounting Causing High
Fuel
Level

in
Carburetor

Low
Compression Valves Sticking

Spark
Plugs Bad

Spark
Plug Cables Bad Weak
Coil
or Condenser Improper Valve Tappet Clearance

Carburetor
Air Cleaner Dirty
High Oil Level in Air Cleaner Dragging Brakes

Front
Wheels Out of Alignment
Tires
Improperly Inflated Inaccurate Odometer

Faulty
Fuel
Tank
Cap

Clogged
Muffler or Bent Exhaust Pipe

Lack
of Power
Low
Compression Ignition System (Timing Late)
Improper Functioning Carburetor or
Fuel
Pump

Fuel
Lines
Clogged
Air
Cleaner Restricted
Engine Temperature High Improper Tappet Clearance
Sticking Valves Valve Timing Late

Leaky
Gaskets
Muffler
Clogged
Bent Exhaust Pipe

Defective
Spark Plugs—Clean or Replace
Defective
Breaker Points—Replace
Points

Incorrect Breaker Point Gap—Reset
Points

Defective
Condenser or Coil—Replace
Loose Electrical Connections—Locate and Tighten
Broken Valve Spring—Replace Spring Broken Piston or Rings—Replace
Defective
Head Gasket—Replace Gasket
Cracked
Distributor Cap—Replace Cap

Low
Compression
Leaky
Valves
Poor Piston Ring Seal Sticking Valves
Valve Spring Weak or Broken
Cylinder
Scored or Worn
Tappet Clearance Incorrect
Piston Clearance too Large
Leaky
Cylinder Head Gasket
Burned Valves and
Seats
Sticking Valves or too Loose in Guides Improper Timing
Excessive Carbon Around Valve Head and Seat Overheating
Valve Spring Weak or Broken Burned Valves and Seats—Continued
Valve Tappet Sticking
Valve Tappet Clearance Incorrect
Clogged
Exhaust System
Valves Sticking Warped Valve Improper Tappet Clearance
Carbonized or Scored Valve
Stems
Insufficient Clearance Valve Stem to Guide
Weak or Broken Valve Spring Valve Spring Cocked Contaminated Oil
Overheating Inoperative Cooling System
Thermostat Inoperative Improper Ignition Timing
Improper Valve Timing
Excessive Carbon Accumulation

Fan
Belt too Loose

Clogged
Muffler or Bent Exhaust Pipe

Oil
System Failure
Scored or Leaky Piston Rings

Popping-Spitting-Detonation
Improper Ignition
Improper Carburetion
Excessive Carbon
Deposit
in Combustion
Cham­
bers
Poor Valve Seating Sticking Valves
Broken Valve Spring Tappets Adjusted too Close

Spark
Plug Electrodes Burned
Water or Dirt in
Fuel
Clogged
Lines Improper Valve Timing
Excessive Oil Comsumption Piston Rings Stuck in Grooves, Worn or Broken Piston Rings Improperly Fitted or Weak Piston Ring Oil Return
Holes
Clogged
Excessive Clearance, Main and Connecting Rod
Bearings

Oil
Leaks at Gaskets or Oil Seals
Excessive Clearance, Valve Stem to Valve Guide (Intake)

Cylinder
Bores Scored, Out-of-Round or Tapered Too Much Clearance, Piston to Cylinder Bore
Misaligned Connecting Rods
High Road
Speeds
or Temperature
Crankcase
Ventilator Not Operating
Bearing Failure
Crankshaft
Bearing Journal Out-of-Round

Crankshaft
Bearing Journal Rough

Lack
of Oil
Oil
Leakage
Dirty
Oil

Low
Oil Pressure or Oil Pump Failure
Drilled
Passages
in Crankcase or Crankshaft
Clogged

Oil
Screen Dirty Connecting Rod Bent 70

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

Dl
Dl-104.
SERVICE
DIAGNOSIS

Poor Fuel Economy
Ignition Timing Late or Spark Advance Inoperative

Carburetor
Float Setting Too High
Accelerator Pump Improperly Adjusted
Fuel
Pump Pressure High

Fuel
Line
Leakage

Fuel
Pump Diaphragm Leakage
Cylinder
Compression Low
Valves Do Not Seat Properly
Spark
Plugs
Defective

Spark
Plug Cables
Defective

Ignition
Coil
or Capacitor
Defective

Carburetor
Air Cleaner Dirty

Brakes
Drag
Wheel Alignment Incorrect

Tire
Pressure Incorrect Odometer Inaccurate

Fuel
Tank
Cap Clogged or
Defective

Muffler or Exhaust Pipe Clogged or Bent

Lack
of
Power
Cylinder
Compression Low
Ingitdon Timing Late

Carburetor
or
Fuel
Pump Clogged or
Defective

Fuel
Lines Clogged
Air
Cleaner Restricted
Engine Temperature High Valves Do Not Seat Property

Valve
Timing Late Intake Manifold or Cylinder Head
Gasket Leaks
Muffler or Exhaust Pipe Clogged or Bent
Spark
Plugs Dirty or
Defective

Breaker
Point Gap Incorrect
Breaker
Points
Defective
Ignition
Coil
or Capacitor
Defective

Electrical
Connection Loose
Broken
Valve Spring

Broken
Piston Ring or Piston
Cylinder
Head Gasket
Defective

Distributor Cap Cracked

Low
Compression
Valves Not Seating Properly Piston Rings Seal Poorly
Valve
Spring Weak or Broken
Cylinder
Scored or Worn
Piston Clearance Too Great

Cylinder
Head Gasket Leaks

Burned
Valves and
Seats
Valves Stick or Are Too Loose in Guides
Valve
Timing Incorrect

Valve
Head and Seat Have Excessive Carbon
Engine Overheats

Valve
Spring Weak or Broken

Valve
Lifter Seized or Collapsed
Exhaust
System Clogged
Valves Sticking

Valve
Stem Warped

Valve
Stem Carbonized or Scored

Valve
Stem Clearance Insufficient in Guide

Valve
Spring Weak or Broken

Valve
Spring Distorted
Oil
Contaminated

Overheating
Cooling System Inoperative
Thermostat Inoperative Ignition Timing Incorrect

Valve
Timing Incorrect
Carbon
Accumulation Excessive

Fan
Belt Loose
Muffler or Exhaust Pipe Clogged or Bent

Oil
System Failure
Piston Rings Worn or Scored
Popping,
Spitting,
Detonation
Ignition Timing Incorrect

Carburetion
Improper

Carbon
Deposit
in Combustion
Chambers Excessive
Valves Not Seating Properly
Valve
Spring Broken
Spark
Plug Electrodes Burned
Water or Dirt in
Fuel
Fuel
Line
Clogged
Valve
Timing Incorrect

Excessive
Oil
Consumption
Piston Rings Stuck in Grooves, Weak,
Worn,
Broken, or Incorrectly Fitted

Crankshaft
Main Bearings or
Connecting Rod Bearings Have
Excessive Clearance
Gaskets or Oil Seals
Leak

Cylinder
Bores Worn, Scored,
Out-of-Round or Tapered
Pistons Have Too Great Clearance to Cylinder Bores
Connecting Rods Misaligned High Road Speed
High Temperature

Crankcase
Ventilation System Inoperative
Bearing Failure
Crankshaft
Bearing Journal Rough or Out-of-Round

Oil
Level Low
Oil
Leakage

Oil
Dirty
Oil
Pressure Low or Lacking
(Oil
Pump Failure)

Drilled
Passages
in Crankshaft or
Crankcase
Clogged

Oil
Screen Dirty
Connecting Rod Bent 105

E

FUEL
SYSTEM
E-78. SERVICE DIHGNOSIS
Symptoms Probable Remedy

Excessive
Fuel
Consumption:
Tires
improperly inflated Inflate

Brakes
drag Adjust
Engine
operates too cold Check thermostat
Heat control valve inoperative Check thermostatic spring
Leak
in fuel line Check all connections

Carburetor
float level high. See
"Carburetor"
section
Accelerator pump not properly adjusted Adjust

Leaky
fuel pump diaphragm Replace
Loose
engine
mountings causing high carburetor fuel level Tighten Ignition timing slow or spark advance stuck See "Distributor" section

Low
compression. Check valve tappet clearance
Air
cleaner dirty
.
Remove and clean

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
compression Check valves

Distributor
points—dirty or pitted Replace

Weak
condenser or coil Replace

Carburetor
jets restricted Remove and clean

Excessive
engine
heat See "Engine" section

Engine
Stalls—Won't Idle:
Improper
condition of carburetor See
"Carburetor"
section

Low
speed
jet restricted Remove and clean
Dirty
fuel sediment bowl screen Remove and clean

Air
cleaner dirty Remove and clean

Leaky
manifold or gasket Replace

Fuel
pump diaphragm porous. Replace
Loose carburetor. Tighten
flange
nuts

Water
in fuel
Drain
and clean system

Improper
ignition. .See "Distributor" section

Spark
plugs Clean and adjust

Valves
sticking.
Grind
valves 134

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
H

FIG.
H-52—MAIN
LIGHT SWITCH (LATE)
1—
Circuit
Breaker

2—
Light
Switch

3—
Rear
Lights

4—
Head
Lights
5—
Parking
Lights
The
light switch shown in
Fig.
H-51 was superseded
by the one shown in
Fig.
H-52.

H-127.
Headlight Dimmer Switch To
remove the headlight dimmer switch, first raise
the hood and disconnect the wires attached to the

switch.
Then
remove the two screws that hold the

dimmer
switch to the floor board. Remove the

switch.
Check
the operation of the dimmer switch

with
a
test
light. A
circuit
across two different pairs of contacts (one to headlights, the other to the
high-beam indicator light) should alternately light
the
test
lamp when the switch is operated.
H-128.
Stop Light Switch
The
stop
light switch is of the diaphragm type.

Should
the switch
become
inoperative, it is neces­

sary
to install a new one.
Current
production vehicles are equipped with two
stop
light switches
that operate independently of each other. Both
switches are located along the
left
side of frame, in the front and
rear
brake lines.

Caution:
Do not apply the brakes while making
this exchange as air may enter the hydraulic line.
Bleed
the brakes after replacing the switch.

Fig.
H-54 shows the wiring of the
stop
light
circuit.
11500

FIG.
H-53—STOP
LIGHT SWITCH
FIG.
H-54—STOP
LIGHT CIRCUIT

1— Stop
Light
Switch
2—
Light
Switch

3—
Tail
Light
H-129. Head Lamp Service

H-130.
Head Lamp Replacement

Refer
to Fig. H-59.

Each
sealed beam head lamp can only be replaced as a
complete
unit.

A
sealed beam unit may be replaced by the fol­ lowing procedure:

a.
Remove door screw.

b.
Remove door.

c.
Remove retaining screws and retaining
ring.

d.
Remove sealed beam unit.
Installation
of sealed beam unit is the reverse of
above procedure. When replacing head lamps,

check
lamp aim following procedures described in

Par.
H-132.

FIG.
H-55—PARKING
LIGHT (EARLY)

1—
Bezel

2—
Lens

3—
Bulb

4—
Gasket
5—
Housing
and Cable

6—
Screw
213