four wheel drive JEEP CJ 1953 Service Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 1953, Model line: CJ, Model: JEEP CJ 1953Pages: 376, PDF Size: 19.96 MB
Page 3 of 376
'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL
A
GENERAL
DHTfl
Contents
SUBJECT
PAR.
General
A-l
Vehicle
Description .A-2
Vehicle
Identification A-3
Identification
Number Location A-4
Serial
Number Location A-5
Engine
Code Number A-6
Plate-And-Trim
Option Plate A-7
General
Specifications A-8
A-1.
GENERAL
This
manual is provided for the guidance of all
automotive service men, vehicle owners, and service salesmen who
repair,
maintain, or adjust
the 'Jeep' Universal Series vehicles. The information herein was prepared from the service man's
viewpoint to
give
him the accurate and concise
data
he may need to service the entire vehicle.
The
information is not elementary as it is intended
for automotive service men who are familiar with
automotive construction and repair in general. It is not intended, nor would it be possible in such
limited
space, to cover every possible repair that he may encounter. All specifications are in accord
with
Engineering Specifications and should be
adhered
to in all work on the vehicle.
The
manual sections follow logical division into
major
components of the vehicles. The first
page
of each section has a detailed index of the
contents
of that section. Subject matter covers all models
included
in this manual unless an exception for a
particular
model is specifically mentioned.
Specifications and components covered were for
standard
production models of 'Jeep' vehicles
current
at the time the manual was approved for
printing.
'Jeep' Corporation reserves the right to
discontinue models at any time or change specifi
cations or design of any of its models without
notice and without
incurring
any obligation.
A-2.
Vehicle Description
This
manual covers all standard production 'Jeep'
Universal
models currently being produced at the time this manual was approved for publication.
Significant
changes made in each model since it
was first produced are included in the manual.
A
description of each model follows.
General
specifications for each model are listed in Par. A-8. Detailed specifications covering major vehicle units
are
listed at the end of each section of the manual.
CJ-3B
—
This
is a 4-wheel-drive 'Jeep' Universal
model, equipped with the four-cylinder
Hurricane
F4-134 engine. Wheelbase is 80".
CJ-5
CJ-5A
— These are 4-wheel-drive 'Jeep' Universal models, equipped with either the Daunt
less
V-6 engine, or the four-cylinder
Hurricane
F4-134 engine. Wheelbase is 81".
CJ-6
CJ-6A
— These are 4-wheel-drive 'Jeep' Universal models, equipped with either the Daunt
less
V-6 engine, or the four-cylinder
Hurricane
F4-134 engine. Wheelbase is 101".
DJ-5
DJ-6
— These are 2-wheel-drive 'Jeep' Universal models, equipped with the four-cylinder
Hurricane
F4-134 engine. DJ-5 wheel- base is 81". DJ-6 wheelbase is 101".
A-3.
Vehicle Identification
Each
'Jeep' vehicle model series has one or more
serial
number prefixes to identify it. Complete
identification of a specific vehicle requires the
prefix
plus the
serial
number.
Serial
numbers are
consecutive for each prefix grouping. Prefix infor
mation following
will
identify the 'Jeep' models
shown by
serial
number prefix from model inception to date.-.
••
' . -
Note:
Vehicles with a
serial
number prefix of five
(5) or more digits that have an S, 5, or 7 as the last
digit are equipped with
Exhaust
Emission
Control.
A
number 1 in the sixth (6th) digit within a seven (7) digit vehicle
serial
number prefix indicates
Left
Hand
Drive;
a 2 indicates Right
Hand
Drive;
a
3 indicates
Left
Hand
Drive
California
Exhaust
Emission
Control
Engine;
a 4 indicates Right
Hand
Drive
California
Exhaust
Emission
Control
Engine.
3
Page 16 of 376
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
Page 80 of 376
Dl
DAUNTLESS
V-6
ENGINE
In
addition to the instructions covering operations
for disassembling the
engine
out of the vehicle, special instructions are given to cover different
operations required when disassembly is
done
with
the
engine
installed.
During
disassembly operations, the
engine
should be mounted in a suitable
engine
repair stand.
Where
practicable, modify or adapt an existing re
pair
stand as necessary to accommodate the
engine.
If
an
engine
repair stand is not used, take care to
perform
disassembly operations in a manner that
will
protect personnel against an accident and the
engine
and its parts against damage.
Dl-6.
Mounting Engine
On
Engine Stand
Refer
to Fig. Dl-4.
a.
With
the
engine
supported by a hoist, remove
the clutch housing and clutch. Match
mark
the flywheel and the clutch cover before disassembly to assure proper reassembly.
b. Position the
engine
on the
engine
stand.
c. Release
some
tension of the hoist cables and secure
engine
to stand.
d.
Make sure the position lock on the
engine
stand
is tight to prevent the
engine
from accidentally
inverting.
e.
Release the hoist cables.
FIG.
D1
-4—ENGINE
MOUNTED
ON
STAND
1—
Spacer
J-8690-6
A—Bolt,
i/2-NC
x 3i/2"
2—
Bolt,
3/a-NC
x 4*/2" 5—Adapter 21316-J 3—
Engine
Mounting Stand
Dl-7.
Remove Intake Manifold
and
Carburetor Assembly
Disconnect crankcase vent
hose,
distributor vacuum
hose,
and fuel line from carburetor. Disconnect two distributor leads from ignition coil. Disconnect
wiring
harness from coolant temperature sending
unit.
Remove ten cap
bolts
which attach intake
manifold to cylinder heads. Remove intake mani
fold assembly and gaskets from
engine.
Dl-8. Remove Exhaust Manifold
The
engine
has two exhaust manifolds. Remove five attaching screws, one nut, and exhaust mani
fold from each cylinder head.
Dl-9.
Remove Distributor
Disconnect vacuum
hose
and wiring harness from
distributor.
Disconnect spark plug cables from
spark
plugs. Remove sparks plugs from
engine.
Pull
spark
plug cable retainers from brackets on rocker
arm
covers. Remove mounting screw, retainer
bracket,
and distributor from timing chain cover.
If
timing chain and sprockets are not to be re
moved from
engine,
note
position of distributor
rotor so that it can be installed in identical position.
Dl-10. Remove
Fuel Pump
Disconnect output fuel line from fuel pump. Re
move
two mounting bolts, fuel pump, and gasket
from
timing chain cover.
Dl-11.
Remove Alternator
and Fan
Belt
Disconnect wiring harness from alternator. Remove nut and flat washer which fasten alternator to
adjustment bracket. Pivot alternator
inward,
to
ward
engine
cylinder block, to relieve fan belt
tension. Remove fan belt from pulleys. Remove
two attaching screws, mounting bracket, and alter nator from right cylinder head of
engine.
Dl-12.
Remove Cooling
Fan and
Water Pump
Refer
to Fig. Dl-5.
Remove four cap screws, lock washers, cooling fan,
fan
hub, and fan drive pulley from flange of water
pump shaft. Remove nine attaching screws, water
pump, alternator adjustment bracket, and water pump from timing chain cover.
Dl-13.
Remove
Oil
Filter
Unscrew
oil filter from
engine
oil pump.
Dl-14.
Remove Starter Motor
Disconnect wiring harness from starter motor and
solenoid. Remove two attaching screws, starter motor, solenoid, and motor attaching bracket from
engine
flywheel housing and cylinder block.
Dl-15.
Remove
Oil
Pressure Sending Unit
Disconnect wiring harness from oil pressure send
ing unit. Remove oil pressure sending unit from
engine
cylinder block.
Dl-16.
Remove
Oil
Dipstick
Withdraw
and remove oil level dipstick and dip
stick
tube
from
engine
cylinder block.
Dl-17.
Remove Crankshaft Pulley
Remove six attaching screws and crankshaft pulley
from
crankshaft vibration damper. 80
Page 82 of 376
Dl
DAUNTLESS
V-6
ENGINE
d.
Use two large screwdrivers to alternately pry
forward the camshaft sprocket and
then
the crank
shaft sprocket, until the camshaft sprocket is pried
from the camshaft. Remove the camshaft sprocket, sprocket key, and timing chain from the
engine;
then
pry the crankshaft sprocket from the crankshaft.
Dl-23.
Remove Rocker Arm Cover
Refer to Fig. Dl-8.
Remove
positive
crankcase ventilator valve from right rocker arm cover. Remove four screws which attach each rocker arm cover to cylinder head.
Remove each rocker arm cover and
gasket
from cylinder head. 14198
FIG.
Dl-6—ENGINE
CRANKCASE
PARTS
1— Connecting Rod Assy.
2— —Piston Pin
3—
Piston and Pin Assy.
4—
Ring
Set 5— Connecting Rod
Bolt
and Nut
6— Connecting Rod Bearing
7— Damper Spring
8— Damper
Bolt
9—
Timing
Chain Damper (Right)
10—
Cylinder
Block
11— Camshaft
12—
Woodruff
Key
13— Camshaft Bearing (No. 1 Front) 14— Camshaft Bearing (No. 2)
15— Camshaft Bearing (No. 3) 16—
Camshaft
Bearing (No. 4
Rear)
31-
17—
Camshaft
Plug
(Rear)
32-18—
Flywheel
33-
19—
Ring
Gear
34-
20— Crankshaft Bearing Set 35-
21—
Main
Bearing Oil Seal
(Rear)
36-
2 2—Crankshaft 3 7-
23—
Main
Bearing Packing Oil Seal
(Rear)
28-
24— Bearing Cap
Bolt
39-
25— Woodruff Key 40-
26—
Timing
Chain Damper
(Left)
41-
27— Damper Bolt 42- 28—
Timing
Chain
43-
29—
Camshaft
Sprocket 44-
30— Crankshaft Sprocket
—Crankshaft
Slinger
—Crankshaft
Shedder
—Crankshaft
Packing (Front)
—Timing
Gear
Cover Gasket
—Timing
Gear
Cover
—Vibration
Damper
-Bolt
-Washer
-Bolt
—Dowel Pin
-Camshaft
Thrust
Retainer and Bolt
—Washer
-Distributor
Drive
Gear
—Fuel
Pump Eccentric
82
Page 102 of 376
Dl
DAUNTLESS
V-6
ENGINE
FIG.
Dl-41—WATER
PUMP
AND
TIMING CHAIN COVER BOLT LOCATION
Cover
Bolts
alternately and evenly 8 to 12 lb-ft. [1,10 a 1,66
kg-m.].
Dl-88.
Install
Crankshaft
Vibration
Damper
a.
Lubricate
the vibration damper hub
before
in
stallation to prevent
damage
to the crankshaft
front oil seal during installation and when the
engine
is first started.
b.
Install
the vibration damper on the crankshaft.
Secure it with its attaching flat washer and screw.
Torque
the screw to a minimum of 140 lb-ft.
[19,35
kg-m.].
Dl-89.
Install
Crankshaft Pulley
Secure the crankshaft pulley to the crankshaft
vibration
damper with six screws. Torque screws 18 to 25 lb-ft. [2,5 a 3,4 kg-m.].
Dl-90.
Install
Oil
Level
Dipstick
Insert
oil level dipstick
into
the dipstick tube.
Dl-91.
Install
Oil
Pressure Sending Unit
Install
oil pressure sending unit in cylinder block.
Connect electrical wiring harness to unit.
Dl-92.
Install Starting Motor
Secure starting motor and
solenoid
assembly to
the flywheel housing and cylinder block with two attaching screws. Torque screw, which attaches this
assembly to the flywheel housing, 30 to 40 lb-ft. [4,1 a 5,5 kg-m.]. Torque screw, which attaches
bracket
to cylinder block, 10 to 12 lb-ft. [1,4 a 1,7 kg-m.].
Dl-93.
Install
Oil
Filter
Install
a new oil filter
element
at oil filter nipple,
at
left
side
of timing chain cover. Torque 10 to 15 lb-ft. [1,38 a 2,07 kg-m.].
D1-94. Install Water Pump
Be
certain that mating surfaces of the water pump
and
timing chain cover are clean.
Install
a new
gasket
on the pump flange. Secure the pump and
alternator adjustment bracket to the cover with
nine attaching bolts. Torque
bolts
6 to 8 lb-ft. [0,83 a 1,10 kg-m.]. Refer to Fig. Dl-41.
D1-9S.
Install
Cooling Fan
Secure the cooling fan, fan hub, and fan drive
pulley to the water pump shaft
flange
with four
attaching screws. Torque screws 17 to 23 lb-ft. [2,35 a 3,18 kg-m.].
Dl-96.
Install
Alternator
and Fan
Belt
Mount the alternator and bracket assembly on
right
cylinder head with two attaching screws.
Torque
screws 30 to 40 lb-ft. [4,1 a 5,5 kg-m.].
Fasten
the alternator
loosely
to its adjustment
bracket
with attaching flat washer and nut.
Install
the fan
belt
on its pulleys. Pivot the alternator
outward,
away from cylinder block, to apply fan
belt
tension. Adjust fan
belt
tension to 80 lb. [36,2 kg.];
tighten
alternator-to-adjustment bracket
nut to secure adjustment
setting.
Connect wiring
harness to alternator.
Dl-97.
Install
Fuel Pump
Install
two mounting
bolts
and new
gasket
on
flange
of fuel pump. Secure pump to timing chain cover with screws; torque screws 17 to 23 lb-ft. [2,35 a 3,8 kg-m.]. Connect
output
fuel line to
pump.
Dl-98.
Install Exhaust Manifold
Secure each of two exhaust manifolds to corre
sponding cylinder head with five attaching screws,
and
one nut. Torque screws and nut 15 to 20 lb-ft. [2,07 a 2,8 kg-m.]. See Fig. Dl-42.
Dl-99.
Install Distributor
Insert
distributor drive gear
into
distributor mount-
FIG.
Dl-42—EXHAUST
MANIFOLD INSTALLATION
1—Torque
Bolts—15
to 20
lb-ft.
[2,07 a 2,8
kg-m.]
102
Page 206 of 376
H
ELECTRICAL
SYSTEM
FIG.
H-42—GROWLER
d.
Install
the armature in starter motor frame,
using care to align the four brushes and brush
springs on the commutator so that they are free to
move
and are square on the commutator.
e.
Install
the thrust washer on the shaft.
Lubricate
the plug and bearing in the end plate.
Install
the
end plate.
Install
the two through
bolts
and tighten securely.
f.
On Prestolite V6 starting motors, check pinion position by measuring from the centerline of the
pinion housing mounting bolt
holes
to the outside
edge
of the pinion.
Correct
measurement with the
Bendix
drive retracted is [19,05 mm.] to
%"
[22,23 mm.]; with drive extended, 1%"
[34,93
mm.] to 1^" [38,10]. Adjust by installing
thrust
washers just inside the commutator end
head or intermediate bearing as required. The
Bendix
drive retaining pin must not project
beyond the outside diameter of the pinion
sleeve.
H-104.
Bench Test
The
motor should first be checked to see that the
free running
voltage
and current are within specifi cations. To
test,
connect the motor to a battery,
ammeter and voltmeter. If the current is too high
check
the bearing alignment and end play to make
sure
there is no binding or interference. Using a
spring
scale and torque arm check the stall torque to see that the motor is producing its rated
crank
ing power. The stall torque
will
be product of the
spring
scale reading and the length of the arm
in
feet.
If the torque is not up to specifications
check
the seating of the brushes on the commutator
and
the internal connection of the motor for high
resistance. The Bendix
Folo-Thru-Drive
should be checked for correct operation. The Bendix pinion
should be checked to see that it shifts when the motor is operated under no load.
H-105.
Bendix Folo-Thru Drive (Prestolite)
The
Bendix
Folo-Thru
Drive is designed to over
come
premature demeshing of the drive pinion
from
the flywheel ring gear until a predetermined
engine
speed is reached. See Fig. H-43. No repairs or adjustments are possible on this
drive
and a
complete
new unit must be installed
if
trouble develops.
H-106.
Lubrication
of
Folo-Thru Drive
A
periodic cleaning and relubrication of the drive is advisable, the frequency of which
will
depend on
the type of service to which the vehicle is sub
jected and the locale of operation.
a.
Remove the starting motor from the
engine
and take off the outboard housing. The pinion and
barrel
assembly
will
be in the demeshed position
on the screwshaft. Do not
move
it forward
until
after
that portion of the armature shaft ahead
of the pinion has been cleaned. If accidentally ro
tated to the outer end of the screwshaft it
will
lock
in that position and cannot be forced back.
b.
Do not disassemble the drive for any reason.
c.
Do not dip or wash the drive in any cleaning solution.
d.
Do not remove the drive from the armature
shaft. Remove
excess
oil, grease or foreign matter
from
the armature shaft by wiping it with a clean cloth.
3
10859
FIG.
H-43—BENDIX
FOLO-THRU DRIVE
Dampen
the cloth with kerosene if necessary. A
light film of
SAE
10 oil may then be applied to the shaft.
e.
Now rotate the pinion and
barrel
assembly to the
fully
extended position, thereby exposing the screw shaft triple threads. Use a cloth dampened with
kerosene to wipe them clean. Do not use
gaso
line
or any
commercial cleaner.
If the dirt is
thick
and gummy, apply the kerosene with a small
brush.
Tilt
the starting motor so that a small
amount
will
run under the control nut. Relubricate
with
a thin film of
SAE
10 oil. Use SAE 5 at ex tremely low temperatures.
f.
Reassemble the starting motor to the
engine
with the drive in the extended position.
Carefully
mesh the pinion with the flywheel ring gear before
tightening the starter motor mounting bolts. It may 206
Page 217 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
H
cuit
lights,
the
signal switch
is
inoperative
and
must
be
replaced.
H-139.
Hazard
Warning Lights
All
current production vehicles
are
equipped with
a
four-way flasher warning system.
The
control switch
is
located
on the
instrument panel left
of
the steering column.
With
the
switch pulled
out,
the
two
front and
two
rear
turn
signal lights flash
on and
off
simultaneously,
as do
both
turn
signal
indicator
lights
on the
instrument clusters.
H-140.
Marker
Lights and Reflector Assembly
The
marker
lights
and
reflector assemblies
on
current
production vehicles
are
mounted
on the
side
of
the front fender and
on the
side
of
the
rear
quarter
panel.
The
spare wheel also mounts
a
marker
light. Some earlier production vehicles have
reflex reflectors mounted on the side of the hood and
on
the
side
of
the
rear
quarter panel. determine
if
dash wiper switch or wiring
is at
fault,
disconnect wiring harness from wiper motor
and
try
operating wiper independently
of
dash switch.
If
still
inoperative
see
procedure under
Par.
H-145.
b. Wiper
will
not
shut
off
— Determine
if
wiper
has both
low
and high speeds, slow speed only,
or
high speed only.
It is
important that
the
wiper
operates
at low
speed during parking cycle.
Dis
connect wiring harness from wiper motor
and try
operating wiper independently
of
dash switch.
If
wiper
shuts
off
correctly with
crank
arm
in
park
position and wiper has both speeds, check
the
lead
between
terminal
and
dash switch ground
and
check
for
defective dash switch.
If
wiper shuts
off
correctly,
but has
high speed only, check lead
be
tween wiper terminal and dash switch
for an
open
circuit
and check
for
defective dash switch.
If
still
inoperative,
see
Par. H-145.
c. Wiper
has
only fast speed.
Check
for
defective dash switch
or
open lead
between
terminal
and
dash switch.
H-141.
Windshield Wiper System
Early
production vehicles equipped with
the
Dauntless V-6
engine
have
two
single speed wind
shield wiper motors mounted above
the
windshield inside
the
vehicle. The wiper motors
are
operated
and
controlled
by a
switch located
on the
instru
ment panel.
Current
production vehicles with stationary wind
shield have
a
two-speed
electric windshield wiper motor mounted below
the
windshield outside
the
vehicle on the driver's side. The wiper motor switch is located
on the
instrument panel
to the
left
of
the steering column.
H-142.
Two-Speed Wiper Motor
The
two-speed
electric wiper motor
is
operated and
controlled
by a
turn
type, three poled, dash switch,
containing
a 6
amp. circuit breaker.
Current
flow
is directed from
the
battery through
the
ignition
switch
to the
wiper dash switch assembly
to the
two-speed
wiper motor, which passes current from the designated motor brush (high,
low or
park)
to
the armature circuit
to
ground.
H-143.
Troubleshooting Procedure
Troubleshooting procedures
are
divided into
two
categories: wiper troubleshooting
in
vehicle; wiper
troubleshooting
on
bench.
Fig. H-65 and H-66
illustrates connecting leads
of the
two-speed
wiper for either bench operation
or to run
wiper inde
pendently
of
dash switch and vehicle wiring when
installed
in the
vehicle.
H-144. Wiper Troubleshooting
in
Vehicle
Typical
wiper troubles and remedies are
as
follows
:
a.
Wiper
is
inoperative
—
Check
wiper switch
cir
cuit
breaker; wiring harness connection
at
wiper
motor
and
wiper switch; wiper motor
feed
wire
from
ignition starter switch
to
wiper switch;
and
check wiper
on
switch
to be
securely mounted.
With
ignition switch
on,
check
for 12
volts
at
har
ness
terminal that connects
to
wiper terminal.
To
BLACK
PARK
GREEN *-
RED m~
LOW
PARKING
<^^>
SWITCH
V^-O*'
HIGH
FIG.
H-64—WIRING
DIAGRAM
FIG.
H-65—WINDSHIELD
WIPER
SWITCH
ASSEMBLY
(EARLY)
1.
Park
(black)
2. Low (green)
3.
High (red)
d.
Wiper
has
only slow speed
and
shuts
off
with
dash switch in high speed position. Reverse harness
leads that connect
to
wiper terminals.
e. If
blades
do not
return
to
park
position when
wiper
is
turned
off,
check wiper ground connection
to vehicle body. Remove wiper from vehicle
and
check
for
dirty, bent,
or
broken
park
switch con
tacts.
f.
If
wiper speed
is
normal
in
slow,
but too ex
cessive
in
fast speed, check for an open terminal. 217
Page 239 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
J
THREE-SPEED
TRANSMISSION
Contents
SUBJECT
PAR.
GENERAL
J-l
TRANSMISSION
SHIFTING
CONTROL.
. J-2
TRANSMISSION
REMOTE
CONTROL
ADJUSTMENT
J-3
REMOTE
CONTROL
DISASSEMBLY
J-4
REMOTE
CONTROL
REASSEMBLY.
. . . . J-5
TRANSMISSION
REMOVAL
J-6
SEPARATING
TRANSMISSION
AND
TRANSFER
CASE
J-7
SUBJECT
PAR.
DISASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-8, J-12, J-16
Transmission
Cleaning and
Inspection J-10, J-18
Transmission
Interlocking Sleeve Inspection J-9
REASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-ll,
J-14, J-19
SERVICE
DIAGNOSIS
J-20
TRANSMISSION
SPECIFICATIONS
J-21
J-1.
GENERAL
A
three speed synchromesh transmission is standard
equipment on all 'Jeep' Universal vehicles.
The
models T90 and T96 transmissions are used
with
the
Hurricane
F4 engine, and models
T86AA
and
T14A transmissions are used with the Daunt
less
V-6 engine. All model transmissions are similar
in
design with exception of the T14A which is a
fully
synchronized (all forward gears) transmission
with
helical drive gears throughout.
The
transmission assembly is attached to the
rear
face of the flywheel bell housing and is supported on a rubber insulator at the frame center cross member which forms the
rear
engine
support.
All
4-wheel-drive vehicles are equipped with a
transfer
case attached to the
rear
of the transmission.
Transfer
case service and repair procedures
are
described in Section
K.
Models
CJ-5A,
and
CJ-6A
are equipped with the
same transmission, but with a remote control shift.
Models DJ-5 and DJ-6 are equipped with a similar
transmission,
however, the construction is
some
what different because it is not designed to receive a transfer case for four-wheel drive.
For
DJ-5 and DJ-6 2WD vehicles, the trans mission repair procedures begin with Par. J-12.
J-2.
TRANSMISSION SHIFTING CONTROL
The
shift of the three-speed transmission is smooth
and
positive. The cane control lever shifts the trans
mission gears direct from the shift control housing
mounted to the top side of the transmission housing.
The
remote control lever shifts the transmission
gears through remote control rods attached to the
adjusting
levers of the shift shafts protruding from the left side of the transmission housing. Poppet
balls and springs retain the transmission gears in mesh and an interlocking mechanism prevents
shifting into two gears at the same time.
J-3.
Transmission Remote Control Adjustment
•
Early
CJ-5A,
CJ-6A
First
disconnect the transmission shift rods from the remote control levers.
Check
for binding of
the remote control shaft on the steering column
and
make the necessary corrections to eliminate any binding condition.
If
the shift is not smooth and positive, first make
sure
the gears are in neutral position then remove
the shift rods at the transmission by removing
clevis pins, Fig. J-l No. 17, and slip a short piece
of snug fitting 34" [6,35 mm.] aligning rod, through
the gearshift levers and housing as shown in insert
drawing.
This
places the clutch and shift lever assemblies
in
the neutral position. Adjust the shift rod yokes
at the transmission end, so clevis pins can be in stalled freely without moving the shift levers on the
transmission after which remove alignment pin.
If
shifting from first to second is difficult or trans
mission hangs in first gear, shorten the low and
reverse shift rod one
turn
at a time until the con
dition is corrected. Usually three turns are re
quired.
Should
the fault continue after completing the above adjustment, check further as outlined below.
First
remove the lubricating fitting. Use a narrow
feeler
gauge
which
will
enter the opening for the
lubricator
and check the clearance
between
the
faces of the shifting clutches.
This
clearance should
be .015" to .031", [W to W]
[0,397-0,794
mm.]. If
this clearance is greater the assembly must be removed for adjustment. The shift dog, which
engages
the clutch slots, should not have more than .009" [0,229 mm.] clearance in the slots. If the clear
ance
between
the clutch
grooves
and cross pins is
too great,
these
parts must be replaced.
J-4.
Removal
of
Remote Control
m
Early
CJ-5A,
CJ-6A
•
Refer to Fig. J-l
To
remove the remote control the following pro cedure is
suggested:
a.
Remove shifting rods from the transmission
and
also from the steering remote control clutch levers. 239
Page 265 of 376
'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
Page 267 of 376
'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