UIILLY' TEEPINDEX OF SERVICE OPER,ATIONS

PAGE NO.

BRAKESAdiustmenls . . . . . . . . t12

Brake Cyl inder Sizes . . . . . . . l l 14

Hydraul ic Brale Syslem . . . . . . I 12

Masler Cyl inder, Replace . . . . . | 130

Trouble Shooi ing 3l

CLUTCHClutch Pedal , Adlust . . . . . . . . ' | 123

Clulch, Replace . . . . . . . . . . . . . l l23

Trouble Shool ing 13

COOLING SYSTEMRadiator, Replace . . . l12l

Trouble Shoot ing

Wafer Pump Repairs . . . . . . . l l2 l

Waier Pump, Replace . . . . . . .1121

ELECTRIC SYSTEMDash Gauge Service . 85

Distr ibutor, Replace . . . . . . . . I l2 l

Dis l r ibutorService. . . . . . . . . . 46

Disfr ibutor Speci{ icat ions . . . .1113

Generator & Regulalor Service . . . . . . . 62

Generator & Regulalor Specs. . . . . . . . .1 1 12

Horn Bufton or Ring, Replace . . . . . . . .1131

fgni t ion System Service . . . . . . . . . 46

lgni l ion Timing

Slarter Swilch Service . 83

Sfarfing Molor Service 77

Start ing Motor Speci{ ical ions . . . . . . . . l l l3

Trouble Shoot ing l0

Turn Signal Troubles 12

ENGINECamsha{t , Replace . . . . . . . . . l l lS

Cranksha{ i & Bear ing Specs. . . . . . . . . .1111

Crankshaf+ Oi l Seal , Replace . . . . . . . .1121

Cyl inder Head, Replace . . . . .1115

Engine, Replace . . . . . . . . . . . . . l l 14

PAGE NO.

ENGINE cont inuedMain Bear ings, Replace . . . . .1 120

PislonPins,Replace . . . . . . . . .1120Pislon Rings, Replace . . . . . . . | 120

Piston, Pin & Ring Specs. . . . | | | |

Pis lons & Rods. Remove . . . . .1 1 19

Piston & Rod. Assemble . . . . . l l19

Pislons, Replace . . . . . . . . . . . .1120

Rocker Arms . . . . . . .1116

Rod Bear ings, Replace . . . . . . | 120

Timing Case Cover, Replace . . . . . . . . . l l lSTiming Chain, Replace . . . . . . l l19

Timing Gears, Replace . . . . . . l l19Trouble Shoof ing 4Valves,Adiust . . . . . l l16

Valves, Gr ind . . . . . . . .1118

Valve Guides, Replace . . . . . . I l18

Valve Li f fers . . . . . . . . l l lS

Valves, Remove . . . . . . . . . . . .1117Valve Spr ing Instal led Heighi . . . . . . . . l l lSValve Spr ing Tesl ing . . . . . . . .1118Valve Speci f icaf ions . . . . . . . . .1112

ENGINE OILINGOil Pan, Replace . . . . l l2 lOi l Pump Repairs . . . . l l2 lTrouble Shooting . . . . 9

FRONT SUSPENSIONCamber, Adlusi . . . . l l30

Casler, Adiust . . . . .1130

Fronl End Repairs . . . . . . . . . .1131

Toe-in, Adiust . . . .1130Trouble Shool ing . . 33Wheel Al ignmenl Speci f icaf ions . . . . . . I l14

FUEL SYSTEMCarbureiors . . . . . . .1122Fuel Pumps . . . . . . . . 96Trouble Shooting 4

"LIYE" FRONT AXLE . . . . . . .n2e

PAGE NO.

OVERDR|VE.. . . . . . . . . . . . rooTrouble Shooi ing . . . . . . . . , . . . 14

REAR AXLEArfe Sha{t , Replace . . . . . . , . .1127General Service . . . . 102Rear Axle Repairs . . . . . . . . . . l l28Rear Axfe Assembly, Replace . . . . . . . .1127Rear Ar le Speci{ ical ions . . . . .1114Trouble Shoot ing 3 |

SPECIFICATIONSBrake Cyl inder Sizes . . . . . . . .1114Capaci ty Dafa . . . . . .1112

Carburelors , . . . . . . | 123Cool ing System . . . . l l l2Cranlshaf l & Bear ings . . . . . . .1111Dislr ibufors . . . . . . . | | 13

Engine Tighfening . . . . . . . . . .1113Generalor & Regulalors , . . . .1 1 12

Pislons, Pins & Rings . . . . . . . .1111Rear Axle . . . . . . . . . I l14

Slar l ing Molors . . . . l l13Tune Up . . . l l l lValve Timing . . . . . . . l l19Yalves . . . . .1112Wheel Al ignmenl . . . . . . . . . .1114

STEERING GEARSHorn But lon or Ring, Replace., . . . . . . l13lSleer ing Gear Repairs . . . . . .1131Steei ing Gear, Replace . . . . . I 13 |

Steer ing Wheel, Replace . . . . . . . . . . . .1131Trouble Shoot ing 33

TRANSFER

TRANSMISSIONSGearshi f t , Adiust . . . .1127Transmission Repairs . . . . . . . .1126Transmission, Replace . . . . . . . .1124Trouble Shoofing 14

TUNE UP . . . 38

WILLYS JEEP

GEN ERAL SPECI FICATIONS

ValveLocat ion

Borc rnd Strolc

PistonDis-

place-me nt,Cubiclnchea

Com-PreE'sionRatio

(Stand.erd)

MaximurnBrakeH.P.@

R.P.M.

MaximurnTorqucLbs. Ft.

@R.P.M.

Modcl Der ignet ion

JEEPS

3.1250x4.3751 134

| 3.1250 x 4.375 | 134

STATION WAGONS

1953 | 4

1953-6lt 4

t954-6l l 6

2000 3535353535

6.90l6t

t t7@l

ll7 @, I

75 @ 4000 r r7@r

@-lntahe valver in heed; exhairst valvec in block.

TUNE UP SPECIFICATIONS

Com-pression

Pressure @Cranking

SpeedMinimum

@-Champion J7 on panenger cars, J6 on other models. @-Auto-Li te. @-Champion.

@-Cam angle variet according to distributor used.

IdleSpeedRPM

lnNeu.tral

PISTONS, PINS, RINGS, CRANKSHAFT & BEARINGS

Fitting Pistone Ring End Gap Main Bear ings

ShaftDiameter

2.333-2.334.0015-.003

ShimToUre

PoundcPull OnScale

.".0.1 oil

Wrist-pin

Diam.eter

.006 Mrx.

. uub Max.

. uuo [lex.

.006 Max.

Shaft I BearingDiameter I Clearance

.008 I .El19 l l .

2.250 | .001-.003

@-Fit ringr in tapered bores for clearance lirted in tightest pottion of ring travel.

. uub Max.

WILLYS JEEP

VALVE SPECIFICATIONS

Valve Lash

Exh.

ValveSpring

PressureLbs. @ In. rnt.

I t-t.

Stem Clearance Stem Diameter

Intake

WILLYS JEEP.3E4 | .300 1.0015-.00321.002s-.

.260 I .351 t .0007-.0022.001-.003 1.0032-.005 | .3706

@-lntake 153 @ lrt1"r", exhaust 105 @ lztlun".

@-Eaton face valve .012C, Thompron Roto Valve .016C.

@-lntake 140 @ lrs1""'r , exhaust ll0 @ l3/4".

@lntake 30o, exhaust 45o.

@-f ntake lzt7"r" , exhaust 2z/64".

GENERATOR AND REGULATOR SPECIFICATIONSfTo Polar ize Generator: For internal ly grounded systcms, disconnect 6eld lead from regulator and_momentar i ly' - f lash

this lead to regulator battery terminal . For external ly grounded systemE, reconnect the leads to the reg-ulator, then momentar i ly connect a jumper wire f rom the "Arm" to the "Bat" terminals of the regulator.

Generator

Cutout Relay

Vol.tage

to €losePoints

i r .4-t . s€) l vBE-6rosA | 6.s

nal l lE-36 | 1.2-1.

Regulator

CurrentRegu-I ator

Sett ingA mper es

Currentand

VoltageArma-ture

Air Gap,Inch

l3s

145

7.3 | 3s | .0s0

5 | .032 | 7.3 | 4s | .0s0

| 3s | .050

.0507.3

,05014.2

t4.z

l8-36 vRx-60098

I GJP-7202A c-N | 35 I lE-36

@-C-Clockwise. N-Negative. @-At 5 volts. @-At l0 volts.

COOLING SYSTEM & CAPACITY DATA

Cool ing System Data

Eol160l ls

Year & Model

Transmissions

WithOver-dr ivePints

FuelTankGals. srd.

PintsAuto-maticQts.

(i)-For Dermanent typc anti-freeze. @-For alcohol type anti-freeze. @-Add one quart with 6lter change.

@-Modilr with transfer cate 6r/2. @-lncludes transfer case.

WILLYS JEEPENGINE TIGHTENING SPECIFICATIONS*

*torqu-e specifications are fo-r clean and lightly lubricated threads only. Dry or dirtythreads produce increased lriction which prevents accuratc measurement of iightness.

RockerArm Shaft

BracketFt. Lbs.

RockerArm

CoverFt. Lbs.

Connect ingRod

Cap Bol tsFt. Lbs.

MainBeariing

Cap Bol tsFt. Lbs.

Flywheelto

CrankshaftFt. Lbs.

Vibrat ionDamper

OT

PulleyFt. Lbs,

O-For 21r"" bolts 50-55; for 3/8" bolts 35-40.@-For zyru't bolls 50-55; for r%2,, boltE 33-3E.

Spark I Cyl inderPlugs I Head

Ft. Lbr. I Boltr

IntakeManifoldFt. Lbs.

l0(Fl30

100-130

DISTRI BUTOR SPECIFICATIONS

Centr i fugal Advance DataDegrees @ R.P.M. of Dist .

FullAdvance

t@32s

Inches ofVacuumto StartPlungerMove-ment

Inchec ofVacuurnfor Ful lPlungerTravel

MaximumVacuumAdvance,

Dist .Degrees

IAT-4205AI AD-4041

.020l96fF6l l Four l lAY-4401 | CC I 42 | .020 | .2t .28 | 17-20 I None I None

Vacuum Advance Data

Cam I PointAngle, I Open-

Degreesl ing,

l@3s0 | r268s l rAT-4007A I CCI 3e 1.020 l .2r- .2sl17-20 | l@300 |Four I IAD-4008A

DJ-3A I tAY-4012 39 1.020 l .2t- .

@-Stamped on plate r iveted to s ide of d istr ibutor housing.

@-At v iewed from the lop. CC-Counter Cloctwise.

@-Microfarads-ar indicated on a condenser tester.

STARTING MOTOR SPECIFICATIONS

No Load Test

Amperec Volts R.P.M.

4300

Torque Test

1958-61 | Four1958-61 | 6-226

Part No.

MDM-6005MDM-6006 I C

Rota-t ion(,

BrushSpring

Tension,Ounces Volts

2.02.02.02.04.0

5.05.0

67s,6Es lMcH-6203 | C | 42-53 I 6s | 5.0

@-Ar viewed from the drive end. C-Clockwise.

5.0

4400 . I

Amperes

4.0

WILLYS JEEP

REAR AXLE AND BRAKE CYLINDER SPECIFICATIONS

Year ModelRing Gear &

PinionBacklash, Inch

Drive PinionAdjustment

Drive PinionBearingPreload,

Inch Lbs.

Drive PinionBearing

Adjustment

Axle ShaftEnd Play,

Inch

Hydraulic Cylinder Bore Sizer, Inch

Wheel Cyl indet I Marrer

@l crn"a"r

1953-61 ShimE .003-.007 I I953-61 Station W .004-.009 Shims t2-18 Shims .003-. I953-61954-61

675, 6856-226

.004-.008

.004-.00EJnt m6

Shims Shims.003-.007 I

I

II

1956-61 | -3A ma Shims l r3/re I

@-Backlash is .005-.007" on CJ-2A up to serial No. 13453. After serial No. 13453 and on al l later models the sett ing is .00rF.00E".

@-Efiect ive with Model 4x473 Serial No. 19523; Model 473 SW Serial No.24122; Model SD Serial No. 14653; Model 673 SW Serial No. 17499the front wheel cylinders were increased frorn l" to lls" and the rear wheel cylinders 1rorr l/gt' to 1".

@-Drive pinion should turn with a slight drag only but with no end play.

WHEEL ALIGNMENT SPECIFICATIONS

Caster, Degrees Camber, Degrees Toe-out on Turns, Degrees

YcarLimits Derired Limits Desired Inner Wheel@

1953-6 l 3/s+ to 3Az

. Wagon II 953-55 675, 685 s/tz to s/sz

to*

r IDJ-34 3/s+ to 3/sz

@-lncorrect toe-out, when other adiustments are correct , genetal ly indicates bent steer ing arms.

@-lncorrect kingpin or knuckle rupport angle with correct camber indicates bent suspension arms or hnuckle support.

Kingpin Angle,Degreer@

1Vz+l+l

l+3 | +3 rr

ENGINE MARKINGSCurrent production engines are marked

with a letter following the serial num-ber when the engine is not . strictlystandard.

The letter "L" means crankshaftiournals are .010" undersize.- The fetter "B" means the bores are.010" oversize,

The letter "C" means .010" oversizebores and .010" undersize crankshaftjournals.

ENGINE, R,EPIACEJeeps

1. Disconnect one battery cable.2. Drain cooling system.3. Remove radiator stay bar on CJ-38.4. Remove radiator and heater hoses.5. Remove fan and fan hub.6. Remove radiator and shroud.7. Disconnect fuel line at pump.8. Disconnect windshield wiper hoses.9. Remove air cleaner and two breather

hoses.10. Disconnect choke and throttle con-

trols,11. Remove starting motor.

ttt4

Engine SectionDisconnect generator wires.Disconnect primary wire at coil.Disconnect heat indicator and oilpressure gauge tubes.Disconnect exhaust pipe from mani-fold.Remove front engine supports. Thiswill allow engine to drop slightlyand will permit access to the twotop bolts on the bell housing.Install a suitable lifting sling on en-gine. Attach sling to hoist and takeup slack.Pull engine forward or roll vehiclebackward until clutch clears bellhousing, and lift engine from vehicle.To install, reverse procedure,

Four-Cylinder Station WagonsDisconnect one battery cable.Drain cooling system.Remove hood and radiator bracerods.Remove heater and radiator hoses.Remove radiator.Disconnect fuel line at pump.Disconnect windshield wiper hose.Remove carburetor air cleaner.Disconnect throttle controls.Remove starting motor.Disconnect generator wires.

Disconnect primary wire at coil.If equipped with overdrive, discon-nect overdrive control wires. (Toavoid possibility of error when con-necting overdrive wires, mark ortag them.)Disconnect heat indicator and oilgauge wires.Disconnect exhaust pipe from mani-fold.Remove engine support bolts.Unfasten bell housing from engine.Install a suitable lifting sling onengine. Raise engine high enough torelieve weight from front enginesupports and pull engine forward,or roll vehicle backward, until clutchclears bell housing. Then remove en-gine from vehicle.To install, reverse procedure.

F-Head 6-Cyl. Station WagonrRemove hood and radiator stay bar.Drain cooling system.Disconnect one battery cable.Remove air cleaner.Disconnect wires f-rom temperaturesender, coil primary and secondaryat distributor, starter solenoid, gen-erator, oil sender.

6. Remove coil.

L2.13.L4.

15.

16.

t2.13.

L7.

L4.

15.

16.L7.18.

1.2.3.4.5.

19.

19.

1.2.3.

4.5.6.l .

8.L

10.11.

WILLYS JEEP

FiS. 2 Six cYlinder heodl ightening. 1953-55 L-Heod

Fig. 3 Six-cylinder F-heqdengine heqd l ightening

Fig. 4 Cylinder heod tighten'ing sequence. 225" engine

Fig. 5 Gylinder heod tightening.iour-cylinder F-head engines

Fig. 6 Position of volveslern guides in six cYlinder148" ond l5 l" L-Heqd engines

Fig. 7 Posirion of vtrlve slem guidesin four cyl inder L-Heod engine

@ooo@

@@-@^@

8.

q

10.11.

72.13.74.15.

16.

8.

L

10.11.

42.13.74.

15.

16.

77.

18.

1.2.D.

4.5.6.

Six cyl inder 148" ond

Disconnect heater hoses at engine.Disconnect throttle link and removechoke control from carburetor'Disconnect accelerator pedal linkfrom throttle bell crank and Pushback into vehicle.Disconnect fuel line at PumP.Disconnect windshielil wiper hosefrom vacuum booster tube.Remove radiator and hoses.Remove exhaust pipe from manifold.Remove bolts from engine front sup-Dorts.bisconnect ground strap at left frontengine support.Remove bell housing-to-rear engineplate bolts and remove - batterYground strap from bell housing ifso attached.The engine is now free of connec-tions and can be lifted from vehicle.To install, reverse Procedure.

"6-226" Station WagonsDrain cooling system.Remove hood and radiator stay bars.Remove radiator hoses and heaterhoses.Remove radiator and shroud.Disconnect battery ground cable.Disconnect wires from temperature

t6l" l-Heod Engine

sender, oil pressure sender, starter,generator, coil and secondary at dis-tributor.Remove air cleaner.Disconnect accelerator pedal linkagefrom bell crank.Disconnect vacuum line from wiPermotor.Disconnect fuel line from PumP.Disconnect engine ground strapfrom front engine support.Disconnect clutch linkage.Disconnect exhaust pipe at manifold.Disconnect front engine supports'The engine is now free of connec-tions and can be lifted from vehicle.To install, reverse foregoing proce-dure.

CYTINDER FIEADBefore the cylinder head is installed,

make certain that all dirt and carbon isremoved from both the head and block.File or hone all high sPots.

Use a torque wrench when tighteningdown cylinder heads. IJneven or exces-sive tightening of nuts may distort cyl-inder bores, causing compression loss andexcessive oil consumption.

Tighten cylinder heads in the sequence

WILLYS JEEP

F.Head four cylinder engine

shown in X'igs. 2 to 5, tightening thema little at a time in the proper order acouple of times around before final tight-ening to the torque values given in theEngine Ti,ghteni,ng Chart. After the en-gine has warmed up to operating temp-erature, recheck the torque and tightenas required.

On F-Head engines, be sure to checkintake valve operating clearances afterthe final tightening.

Note-Tightening cylinder heads on I'-

Fig. E Posilion of volveguides in F-heod enginer

head engines without removing rockerarms may be accomplished with a wrenchhaving an ++" box on one end and a r/2"square box on the other end. This, to-gether with a torque wrench will do thejob.

Service Note

Accura,te alignrnent ol the cEli,nderhead, gasket and, block on L6-226 enginesis required to preuent gasket failure. TuocElittd,er head bolt holes, at oTtposi,te cor-ners of, the head (Ttositi,ons 24 anal 26 xrxFiS. 4) haue a sli,ghtlg smaller di,ameterthan the other holes and, can be used, lorguicle pi,ns.

The guide pi,ns can be made bg cuttingthe heads oll ttoo cgli,nd,er heod, bolts.Cut sl,ots in the end, from which the headsu)ere ren'LoDed, to install and, then retnoyethe guide pins.

The torqui,ng sequence for the heailbolts is shoun xn FiS. 4.

ROCKER ARMSF-Head Engines

To remove the rocker arm assembly,proceed as follows:

1. Remove carburetor air cleaner.2. Disconnect spark plug wires.3. Drain cooling system.4. Remove rocker arm cover.5. Remove rocker arm bracket screws

and lift off rocker arm assembly.Before disassembly, mark rocker arms,

brackets and shaft so they can be reas-sembled in the original positions.

F-Heqd four cylinder engine

VAIVEs, ADJUSTL-Head Engines

The valves may be adjusted when theengine is at normal room temperature.Crank the engine over until the valveto be adjusted is fully closed. Hold theIifter body with a tappet wrench to pre-vent it from turning. Then turn thetappet adjusting screw until the properclearance is obtained. Measure the clear-ance with a feeler gauge and, after ad-justing one tappet, proceed in like man-ner with the others, being certain thatthe valve being adjusted is fully closed.

In addition to the conventional methodof adjusting tappets by locating the dis-tributor rotor and then adjusting thetappets by following the firing orderof the engine, the following method mayalso be used:

F our - C gli,niler E n gi'ne s

Valves Fully Raised Adjust Tappets1and32 and, 56and84and7

6and84and71and3

. 2 and,E

Sin-Cglind,er 748' & 767" Engines

Valves Fully Raised Adjust Tappets

land 3Tand I2and 5

10 and 124and 68 and 11

10 and 124and 6

. 8and11land 3Tand I2and 5

I116

WILLYS JEEPBi,n-Cgli,nd,er 226" Engine

Valves Fully Raiseil Ailjust Tappets

land 38and I2and 6

10 and 124and 57 and 11

10 and 124and 57 and 11land 38and I2and 6

Six-cyllnder F-Hecd engine

F Head EnginesThe exhaust valves (in block) may be

adjusted in the same manner as outlinedfoi L-head engines. Ilowever, the intakevalves may best be adjusted with theengine running after it has warmed upto operating temperature.

If the cylinder head has been tight-ened, be sure to recheck'intake valveclearances and adjust as required.

VALVES, REMOVEL-Head Engines

After removing the cylinder head, takeoff the valve chamber covers and usecloth to block off the holes in the valvechamber to prevent the valve locks fromfalling into the crankcase.

With a suitable valve spring compres-sor, raise the springs on those valveswhich are closed and remove the valvelocks. Then turn the crankshaft untilthose valves which are open are closedand remove the remaining valve locks.

Remove all valves and Place them ina board with numbered holes so they canbe identified as to the valve port fromwhich they were removed.

F-Head Engines!'ollow the same procedure in remov-

ine the exhaust valves from these en-giies as outlined for L-head engines.

In removing the intake valves from thehead a suitable fixture is available whichholds the valves closed and compressesthe spring at the same time.

Checking volveinsrolled hoighr

Fig. 5AsprlngSk-cyllnder F-Heod engine

tltT

WITLYS JEEPVALVE SPRING

INSTAILED HEIGHTWhen valves and seats are reground

the position of the valve in the head ischanged so as to lessen the valve springtension. Without proper valve springtension the valve does not seat longenough or it may not seat completely.Since the valve is cooled by transferringheat from the valve head to the seat andthence to the coolant, improper valyespring tension will cause worn, pitted anddistorted valves which result in loss ofcompressibn and power as weII as poorgasoline mileage.

When valves, springs, retainers andlocks are installed, measure the as-sembled height of valve springs from thesurface of the cylinder head spring padto the underside of the spring retainer asshown in Fig. 5A. If the assembledheight is greater than the dimensiongiven in t};re Vulue Specifications Chart,install a spacer or shim of proper thick-ness between cylinder head spring padand spring to bring the assembled heightto specifications.

Do not i,nstall spacers unless neces-sa,rg. Encesscue use of spacers uill re-sult in ouerstressi,ng ualue spri'ngs anilouerload,ing camshalt lobes tolt'i'ch could,leail to spring brea'kage and, worn cdn'L-shalt lobes.

VATVE SPRING TESTINGAfter taking out the valves, remove

the springs and wash them with gasolineor other suitable solvent. Examine thesprings for damage or corrosion due toacid etching, which will develop into sur-face cracks and cause spring failure.

Check valve spring pressure on aspring testing fixture if one is available.If a fixture is not available, at leastcheck the free length of each spring bystanding it alongside a new spring. Anyspring that does not conform to the pres-sure specifications given in the ValueData chart within 10 per cent should bereplaced. Likewise, any spring thatstands shorter than the new spring usedfor comparison should be discarded'

vAtVE GUIDESAfter the valves and springs have been

removed, clean the valve guides with awire brush, and clean the valves with awire wheel brush, making sure that allcarbon is removed from the top and bot-tom of the heads, as well as the gumwhich might have accumulated on thestems.

Check the clearance between the valvestems and guides carefully. The stand-ard clearances are given in tll,e ValueData, chart.

Excessive clearance between the valvestem and guide will cause improper seat-ing and burned valves. When there is toomuch clearance between intake valvestems and guides, there is a tendency todraw oil vapor through the guide on thesuction stroke, causing excessive oil con-sumption, fouled spark plugs and poorlow speed performance.

Fig. 9 Loyout of volve syslem. Four cylinder L-heodengine. ,-This is rypicol of ihe F-hecd engine excePt thol lheinloke volve mechonism ls conloined ln the cylinder heod

To check valve stem-to-guide clear-ance, take a new valve and place it ineach valve guide and feel the clearanceby moving the valve stem back and forth.If this check shows excessive clearance,it will be necessary to repiace the valveguide. If the clearance is not excessivewhen checking with a new valve but i.sexcessive when checked with the oldvalve, the old valve stem is worn and anew valve must be installed.

If it is necessary to replace the valveguides, the old guides can be driven outwith a special driver which is availablefor the purpose. Ifowever, in lieu of thedriver, the guides can be pulled out byusing a suitable piece of pipe togetherwith a long bolt and suitable washers.

When replacing'the guides. maximumengine performance can only be securedwhen the guides are installed correctly(see tr'igs. 6, 7 and 8).

vA[vEs, GRTNDIn refacing valves, take off the mini-

mum of metal required to clean up thevalve faces. If the outer edge of the valvebecomes too thin or sharp due to exces-sive grinding, the valve must be replaced.

Inspect the valve seats in the blockand head for cracks. burns, pitting,ridges or improper angle. During anygeneral engine overhaul it is advisableto reface the valve seats reg'ardless oftheir condition. If new valve guidesare required, they must be installedbefore refacing the seats if the equip-ment used has a valve guide pilot.

The valve seat width after refacingshould measure not more than 6! in.The width may be checked by placing ascale across the face of the seat.

A simple check can be made to provethe fit of the valve in the valve seatby spreading a thin fllm of PrussianBlue on the valve face and then in-serting the valve into the r/alve seat.

With hand pressure, rotate the valve Y+turn and then remove it and observethe transfer of Prussian BIue to thevalve seat. An uneven transfer ofPrussian Blue will indicate an inaccu-rate valve and valve seat refacing op-eration.

VATVE LIFTERSThese lifters are of the mushroom type

operating in guide holes cast in the block.This means that the camshaft will haveto be removed from the engine if valvelifters require replacement.

Whenever the camshaft is removed,inspect the faces of the lifters wherethey contact the cams and replace anythat are scored, rough or cracked. Checkthe clearance of the lifters in the guides'replacing those that have worn exces-sively. Oversize available is .004 in'and the guides must be reamed to ac-commodate them.

CAMSHAFT & GEARcovER, REPTACE

All Engines (Except 6-226)

1. Drain cooling system.2. Remove radiator and grille or guard.3. Remove cylinder head, valves and

sprrngs.4. On L-head engines, remove mani-

folds.Remove fuel and oil pumps.Remove oil pan.Remove crankshaft pulleY (andvibration damper on 6-cyl.).Remove fan assembly.On CJ-2A and CJ-SA, remove nutsfrom front engine support.Remove engine front cover.Remove camshaft gear and thrustnlate.iie valve lifters up to their highestpoint of travel with string wrappedaround the adjusting screws and

o.6.7.

8.9.

10.11.

72.

WILLYS JEEP

Fig. lO Vclve t iming.Six-cYl. 226" englne

attach to manifold studs. Spring cliptype clothespins or small "C" clampsmay also be used.

13. On- CJ-2A and CJ-3A, raise frontof eng'ine until camshaft will clearfront crossmember.

14. Remove camshaft from engine.15. To install, reverse foregoing proce-

dure and set valve timing as shownin F ig. 10.

"5-225" Engines

1. Drain cooling sYstem.2. Remove radiator.3. Remove vibration damPer.4. Remove timing chain cover.5. Remove timing gears and chain.6. Remove fuel pumP.7. Remove eylinder head.8. Remove oil Pan and oil PumP.9. Remove valves and springs.

10. Hold valve lifters up with springtype clothespins or string to preventthem from interfering with camshaftas it is being withdrawn.

11. Unfasten camshaft thrust plate fromcylinder block and withdraw thecamshaft.

12. To install, reverse removal proce-dure and-set valve timing as shownin F ig. 11.

Fig. | | Yclvc tirnlng forlimlng gcor driven engincs

Flg. 12 Lcyoul of crankshoft ond relsled pqrl5.Four cYlinder engine

VATVE TIMING DATAYear Model Intake Intake Exhaust Exhaust

opens@ Closes@ 0pens@ Closes@1953-61 6-226 Eng. l0 60 55 I0

0thers 9 50 47 12

H€grees before tJp dead center.@---D€grees after bottom dead center.@egrees before bottom dead center.@egrees after top dead center.

I

TIMING CHAIN"6-225" Engines

F'or correct valve timing on this en-nine. install the chain so there are 10[ins'between the sprocket timing marks,Fig. 10.

TIMING GEAR,SAll Ercept "5-226"

The camshaft is driven by a steel gearon the crankshaft and a fibre gear onthe camshaft. Lubrication is positivethrough a jet pressed into the crankcasedirectly back of the contact point of thegears. When the gears are removed,check both the jet and oil passage tompke sure theY are clear.

When it becomes necessary to replacethe timing gears, due attention mustbe given to the end play of both shaftsand running clearance of the gears.

End play of tlte crankshaft is con'trolled by the rurtning clearance be-tween the crankshaft g;ear and g:earthrust plate, Fig. 11. The end play isadjusted by shims placed between thethrust plate and the end of the frontmain bearing. Shims .002 in. thick areavailable for this adjustment. Whenthe thrust plate or washer is removed,be sure it is reinstalled with the beveledinner edge toward the crankcase.

End play of the camshaft is deter-mined by the running clearance betweenthe camshaft 8:ear and thrust plate. Thestandard clearance is .003 to .0055 in.which is determined by the thickness

of the camshaft gear thrust Platespacer, Fig. 9. Should a check indicatenbt enouEh clearance, place a thin shimbetween Ihe thrust plate spacer and theshoulder on the camshaft. Clearancemay be reduced'bY dressing off thespacer slightly. Whenever the spaceri5 installed-. mCke sure that the beveledinner edge is toward the rear.

End play of both the camshaft andcrankshaft can best be measured witha dial indicator.

Standard running clearance betweenthe gears is .000 to .002 in', --whichshould be checked wittr a dial indicator-

To set the valve timing, install thecrankshaft gear followed by the. cam-shaft gear wittr tne camshaft positioTedto all6w installation with the timinggear marks meshed, F ig. 11.

PISTONS & RODS, R,EMOVE

After removing the cylinder head andoil pan, examine the cylinder bores abovethe- rinE travel area. If the bores areworn sd that a shoulder or ridge existsat this point, remove the ridge wit-h aridEe re-amer to avoid damaging ringsor bracking ring lands of pistons duringremoval,

Remove the connecting rod caPs andpush pistons and rods out-of cylinders'hsins-care to prevent rod bolts fromconticting and nicking crankshaft jour-nals.

Make sure the rods and Pistons areproperly numbered so they can be rein'itaUeA in original locations. It is advis-able to install caps on rods to avoid mix'ing parts.

PlsroNs & RoDs,ASSEMBLE

Alf Except "6-226" EngineAs shown in F ig. 13, pistons should be

assembled to the connecting rods so thatthe oil spray hole in the rod faces away

1119

WILTYS JEEPfrom the camshaft side of the enginewith the vertical slot in the piston facingthe camshaft side.

"6-226" Engine

When correctly assembled, the oilspray hole in the rod laces the camshaftside of the engine with the vertical slotin the piston facing away from the cam-shaft side.

PISIONSStandard size service pistons are high

limit or maximum diameter; therefore,they can usually be used with a slightamount of honing to correct slight scor-ing or excessive clearances in eng'ineshaving relatively low mileages. Servicepistons are also furnished in .005, .010,.015, .020 and.030 in. oversizes.

Before a honing or boring operation isstarted, measure all new pistons with amicrometer at points exactly 90 degreesaway from the piston pin. Then selectthe smallest piston for the first fitting.The slight variation usually found be-tween pistons in a set may provide forcorrection in case the first piston is fittedtoo free.

It is very important that refinishedcylinder bores are trued up to have notmore than .0005 in. out-of-round or taper.Each bore must be final honed to removeall stone or cutter marks and provide asmooth surface. During final honing,each piston must be fitted individually tothe bore in which it will be installed andshould be marked to insure correct in-stallation.

After final honing and before the pis-ton is checked for fit, each bore must bethoroughly washed to remove all tracesof abrasive and then dried thoroughly.The dry bore should then be brushedclean with a power-driven fibre brush.

Both the piston and cylinder blockmust be at the same temperature (roomtemperature of 70 degrees) when thepiston is checked for fit in the cylinderbore. Therefore the cylinder should beallowed to cool after boring or honingand before the piston fit is checked. Thisis important because a difference of 10degrees between the temperature of partsis sufficient to produce a variation of.0005 in.

To check the fit of pistons, use a feelerribbon gauge la in. wide and the thick-ness listed in the Piston & Ring Datachart. Insert the piston upside down inthe cylinder bore with rings removed.Locate the feeler 90 degrees from thepiston pin hole, between the thrust faceof the piston and cylinder wall. Hookthe feeler to a spring scale. If the forcerequired to pull the feeler out of the cyl-inder with the scale is as specified inthe chart, the piston fit is correct. If tootight, the cylinder must be honed outuntil the proper clearance is obtained.

PISTON RINGSWhen new piston rings are to be in-

stalled without reboring cylinders, theglazed cylinder walls should be slightlydulled, but without increasing the borediameter. This is done with a "Glaze-

Fig. 13 Assemble pistons ond rods ogshown. All except tt6-225" englne.On. "5-226" the oil sproy hole fqcerthe cqmshsfl side with the verticol pis-lon slot oway from the comshqfl side

buster.l' or with a hone equipped with thefinest grade of stones,

New piston rings must be checked forclearance in piston grooves and for gaFin cylinder bores. Cylinder bores andpiston grooves must be clean, dry andfree of carbon and burrs.

Check the clearance of each ring in itspiston groove by installing the ring andthen insefting feeler gaug:es und,er t}l.ering. Any wear that occurs in the pistongroove forms a step or ridge at the innerportion of the lower land. If gauges areinserted above the ring, the ring may reston the step instead of on the worn por-tion of the lower land, and a false meas-urement of clearance will result.

If the piston grooves have worn to theextent that relatively high steps orridges exist on the lower lands, the pistonshould be replaced because the steps willinterfere with the operation of the newrings and the ring clearances will be ex-cessive. Piston rings are not furnishedin oversize widths to compensate for ringgroove wear.

See the Piston & Ri,ng Data chart forring groove clearances and end gapclearances.

To check the end gap of rings, placethe ring in the cylinder in which it willbe used. Square it in the bore by tappingwith either end of the piston, then meas-ure the gap with feeler gauges. If nec-essary to increase the gap, ffle the endswith a smooth file.

PISTON PINSOn "6-226" engine the pins are of the

full-floating type, being retained by snaprings which fit in grooves cut into thepiston bosses.

On engines other than the "6-226", thepins are locked in the rods and are fittedwith a clearance of .0001 to .0005 in.which is equivalent to a light thumb pushfit with the parts at normal room tem-perature. No oversize pin is availableas it is impossible to ream the connect-ing rod satisfactorily due to the clampslot, and also because the piston platingshould not be removed from the pistonpin bore.

ROD BEARINGSInsert type bearings consist of two half

shells, the upper shell having an oil sprayhole which communicates with the oilhole in the rod.

When the shells are placed in the rodand cap the ends extend slightly beyondthe parting faces so that when the rodbolts are tightened the shells will beclamped tightly in place to insure posi-tive seating and to prevent turning.Th,e enil,s ol the shells must neaer befi,led, flush, witlt' the perti'ng faces of therod a'nd' cap.

If this type bearing beeomes noisy oris worn so that clearance on the crankpinis excessive, a new bearing of propersize must be selected and installed sinceno provision is made for adjustment-Ijnder no circumstances should the rodor cap be filed to adjust bearing clear-ance.

Service bearings are furnished instandard sizes and several undersizes,including undersizes for reground crank'shafts.

The clearances of connecting rod (andmain) bearings may be checked withPlastigage which is available at any autoparts iobber and full instructions for itsirse afe furnished with the envelope inwhich it is contained.

Lacking Plastigage, however, clear-ance may be checked with a .002 in. testshim, s/a in. square. Place the shim be-tween the bearing and shaft iournal.Install the cap, tightening the nuts tothe recommended torque. A locked bear-ing or drag when the rod is moved end-wise on the crankshaft indicates theclearance is correct providing the rodmoves endwise freely without the testshim installed. Do not overlool{ removingthe shim.

The connecting rod nuts are lockedwith stamped nuts which should not beused when once removed. Install the newnuts with the flat face toward the con-necting rod nut. Turn the locking-nutnnger ligtrt and ttren tighten it only ahalf-turn more.

MAIN BEARINGSWhen necessary to remove the crank-

shaft the engine will have to be removedfrom the chassis. And since the mainbearings on all four-cylinder eng'ines aie

WILLYS JEEP

.004'. When proper clearance has beeno_btained, drill a t?', pin hole throughthe drive shaft, install the pin and peEnit securely.

RADIATOR, REMOVERaise the hood, disconnect the upper

and lower hose, unfasten the core fromits mounting and lift it off.

WATER PUMP, REPTACERemove the fan belt and blades. un-

fasten the pump from the cylinder blockand lift it off. On some models, it maybe necessary to loosen the radiator coreand pull it fonvrzard in order to removethe water pump assembly.

WATER PUMP REPAIRSTo disassemble the pump, take out the

bearing retaining wire and press theshaft through the impeller and pumpbody. Remove the seal washer and seal.Place the pump shaft and fan pulley onthe press in such a position that thebearing will clear the opening and pressthe shaft from the pulley.

To reassemble the pump, install thelong end of the shaft in the pump bodyfrom the front end until the outer endof the bearing is flush with the frontend of the pump body.

Dip the seal and seal washer in brakefluid and install in the impeller, Placethe impeller on the bed of the pressand press the long end of the shaft intothe impeller until the end of the shaftis flush with the impeller.

Support the assembly on the impellerend of the shaft and press the fan pul-ley on the shaft so that the end of theshaft is flush with the face of the fanpulley. Move the shaft in the body sothat the grooves in the bearing andpump body line up, then lock in posi-tion with the bearing retaining wire.

DISTRIBUTOR, REPTACEAll Except "6-226" Engines

The distributor is mounted.on the rightside of the engine and is operated by acoupling on the oil pump shaft which isdriven by a spiral gear on the camshaft.1. Remove wires from the distributor

cap, noting the order in which theyare assembled to assure correct re-assembly.

2. Remove primary lead from terminalpost at side of distributor,

3. Disconnect vacuum tube.4. Remove distributor cap.5. Note position of rotor in relation to

the distributor housing. Mark hous-ing to facilitate installing andtiming.

6. Remove screw holding distributor to

Fig. f4 Rofor type oil pump. All except "6-226" engine

held in place by dowels, the engine willhave to be removed when their replace-ment becomes necessary.

Main bearings on six-cylinder enginesmay be removed and installed withoutremoving the engine.

The bearings are made to size and donot require line reaming or adjustrrrent.

When it is necessary to install newbearing shells it.is advisable to measurethe shaft journals with a micrometer fofbeing out-of-round. If an out-of-roundcondition exists in excess of the standardrunning clearance of the bearings (eithefmain or rod) a satisfactory bearing re-placement cannot be made and it will benecessary to replace or reg:rind thecrankshaft. Ilndersize bearings of .010and ,020 in. are available.

Before installing the shaft and bear-ings, use a rifle brush to clean the oilpassages thoroughly in both the shaftand crankcase. If possible, blow out theholes with compressed air. Be sure thejournals are not nicked or scored andthat all parts are thoroughly clean.

After installing: the bearings, check therunning clearance to be sure it is stand-ard (see Engine Bearing Data chart\.Use Plastigage or a .002 in. test shimabout one inch square. Place the shimbetween the shaft and bearing andtighten the bearing cap nuts to the rec-ommended torque. The shaft should belocked if the clearance is at the lowlimit or show a drag if at the high limitwhen turned, proving that the clearanceis correct. Do not overlook removing thetest shim.

CRANKSHAFT OIt SEALThe rear main bearing is sealed ag'ainst

external leakage by a lip type neopreneseal with a metal core. The seal has theadvantage of being able to be slippedinto place without removing the crank-shaft.

For easy installation, give the seal acoat of grease. Be careful not to coatthe ends of the seal as they have sealingcompound applied to them.

OIL PANThe floating oil intake is attached to

the crankcase with two cap screws.'Whenever the oil pan is removed, thefloat. screen and tube should be cleanedthoroughly in a suitable cleaning fluid

to remove any accumulation of dirt. Ifthe screen has been crushed, it is betterto replace it rather than attempt to makea reparr.

OIt PUMPAll Except "5-225" Engines

The oil pump is located externally onthe left side of the engine. When neces-sary to remove the pump, first take offthe djstributor cap and note the positionof the rotor so that the pump may bereinstalled without disturbing the igni-tion timing.

To install the pump without disturb-ing the timing, the pump gear mustbe correctly meshed with the camshaftdriving gear to allow engagement of thedriving key on the distributor shaft inthe pump shaft driving slot withoutmoving the distributor rotor. Assemblycan be made only in one position be-cause the slot and driving key are ma-chined'off center.

To disassemble the pump, Fig. 14, re-move the cover and gasket. Hold ahand over the cover opening and, withthe pump upside down, turn the shaftuntil the outer rotor slips out. Driveout the pin securing the drive gear tothe shaft. Press the shaft out of thegear and slide the shaft and inner rotorout of the body.

X'ailure of the pump to operate at fullefficiency may usually be traced to ex-cessive end play in the rotor or exces-sive clearance between the rotors. Theclearance between the outer rotor andpump body should also be checked.

End play of the rotors is controlledby the thickness of the cover gasketwhich is made of special material whichcan only be slightly compressed. Neveruse other than a standard factory gas-ket.

"5-226" EnginesThe oil pump is of the positive gear

type, located at the bottom of the verticalshaft which also drives the distributor.

To disassemble the oil pump, take offthe screen float. Drive out the pin whichsecures the drive gear to the shaft andtake off the gear. Remove pump coverand gasket. Position the pump with thedrive shaft end up and allow the gearsto drop from the pump body. Do not re-move the idler gear shaft unless wornor damag:ed,

WILLYS JEEPcrankcase and lift unit from engine.

7. Reinstall in the reverse order of re-moval and set the timing as outlinedbelow.

"6-225" EnginesTo remove the distributor, disconnect

the vacuum tube and low tension wireand remove distributor cap. Remove boltand washer that holds advance arm toadapter and lift out distributor. Installthe distributor in the reverse order ofremoval and set the ignition timing asoutlined below.

IGNITION TIMING

Crank engine to bring No. 1 piston upon its compression stroke and stop whenthe timing mark is in the center, of thehole in the flywheel housing or whenthe pointer on the timing gear coverlines up with the specified timing markon the crankshaft pulley or vibrationdamper (see Tune Up Chart). Loosenthe distributor body clamp and rotatethe distributor until the points close.Then turn it in the opposite directionuntil the points just begin to open andtighten the clamp bolt. Check the timingwith a timing light.

When using a timing light, it ts adut's-able to d,isconnect the il'istributor Dacu%n'Lline before bhecking ttrning' otherwisethe timing may be affected due to thefact that the centrifugal advance mayoperate if. the engine is idling too fast,thus obtaining incorrect timing.

Connect the timing light according tothe manufacturer's instructions. Startthe engine and operate at idle speed,Direct the light on the timing mark. Itshould flash just as the timing markIines up with the pointer, indicating cor-rect timing. If the pointer and timingmark does not line up, rotate the dis-tributor as required to bring them inalignment.

Performance Complaints

Flooding, stumble on acceleration orother performance complaints are inmany instances caused by the presenceof dirt, water or other foreigrr matterin the carburetor. To aid in diagnosingthe cause of the complaint, the carbu-retor should be carefully removed fromthe engine',,rithout draining the fuel fromthe bowl. The contents of the fuel bowlmay then be examined for contaminationas the carburetor is disassembled.

Check the fuel in the bowl for contarn-lnation by dirt, water, gum or otherforeign matter. A magnet moved throughthe fuel in the bowl will pick up andidentify any iron oxide dust that mayhave caused intake needle and seatleakage.

Inspect gasketed surfaces betweenbody and air horn. Small nicks or burrsshould be smoothed down to eliminateair or fuel leakage. On carburetors hav-ing a vacuum piston, be especially par-ticular when inspecting the top surfaceof the inner wall of the bowl aroundthe vacuum piston passage. A poor sealat this location may contribute to a "cut-ting-out" on turns complaint.

Fill the carburetor bowl with cleanfuel before installing on manifold. Thiswill help prevent dirt trapped in thefuel system from being dislodged by thefree flow of fuel as the carburetor isprimed. The operation of the float andintake needle and seat may be checkedunder pressure if a fuel pump is usedat the bench to fill the carburetor bowl.Operate the throttle several times andvisually check the discharge from pumpjets.

Cqrburetor SectionPoor Mileage and Engine

Loading Complaints

Cases of poor mileage and engineloading may be due in many instancesto sluggish choke valve opening duringcold driveaway, caused by insufficientvacuum in choke housing:, a plugged orrestricted heat pipe or inlet in chokecover. To check for this condition, haveengine warm and running at slow idle.Remove choke heat pipe and hold afinger over the heat inlet hole (hole is onchoke housing on some carburetors). Ifthere is little or no vacuum pull on thefinger, check the choke housing for gas-ket leaks or plugged vacuum passages.If these are OK, check choke vacuumhousing and manifold.

Dirty or Rusty Choke Housing

In cases where it is found that theinterior of the choke housing is dirty,gummed or rusty while the carburetoritself is comparatively clean, look for apunctured or eroded manifold heat tube(if one is used).

Manifold Heat Control ValveAn engine equipped with a manifold

heat control valve ca,n operate with thevalve stuck either in the open or closedposition. Because of this, an inoperativevalve is frequently overlooked at vehiclelubrication or tune-up.

A valve stuck in the "heat-off" posi-tion can result in slow warm-up, com-bustion chamber deposits, carburetoricing, flat spots during acceleration, lowgas mileage and spark plug fouling.

A valve stuck in the "heat-on" positioncan result in power loss, engine knock-ing, sticking or burned valves and sparkplug burning.

To prevent the possibility of a stuckvalve. check and lubricate the valveeach time the vehicle is lubricated ortuned-up. Check the operation of thevalve manually. To lubricate the valve,place a few drops of penetrating oil onthe valve shaft where it passes throughthe manifold. Move the valve up anddown a few times to work in the oil.Neuer use engine oil for thi's purpose asit wi,ll leaue a resddue which hampersualue operation.

Rough ldle & Low Speed StallingThese engines are equipped with posi-

tive sealed type crankcase ventilationwhich reduces to a minimum condensa-tion and the formation of sludge. Thecorrect operation of the system dependsupon the free flow of air from the car-buretor air cleaner through the oil fillertube and engine to the control valvemounted in the intake manifold.

Be sure there is no air leakage at thetube connection, and that the oil fillertube cap gasket is in good condition.Always keep the cap locked securely.

Be sure that the ventilator valve,mounted in the intake manifold, oper-ates at aIl times. Should the valve be-come clog:Bed with carbon the ventilat-ing system will not operate and a pres-sure will build up in the engine crank-case which may cause oil loss at therear main bearing or by the Pistonrings.

Should the valve fail to seat it willbe impossible to make the engine idlesatisfactorily. When the valve operatescorrectly, a slight vacuum is presentin the crankcase which is of materialassistance in oil control.

Clean the uentilator DalDe each timethe ualues are ground or th'e engi,netuneil.

WILLYS JEEP

CarburetorModel

I YF-2392S1954-6 I1954-55

GD-2052SA Il e53-6 l I A-B-C

l l YF-951 A

CARIER NOIES

METERING ROD

YF-This adjustment must be checked after adjust-ing pump and each time the carburetor is reas-sembled. With throttle valve closed, press down onupper end of d iaphragm shaft unt i l d iaphragm bot-toms in vacuum chamber. Metering rod should con-tact bottom of metering rod well and metering rodarm should contact lifter link at outer end nearestspr ings and at support ing lug. Adjust by bendinglip of metering rod arm to which metering rod isattached.

WGD and WCD-This adjustment must be madeafter pump adjustment. With throttle valves closed,press down on vacumeter link until metering rodsbottom. With rods held down, revolve metering rodarm until lip contacts vacumeter link. Hold in placeand tighten set screw.

CARTER CARBU RETOR ADJ USTMENTS@-With throttle valves closed, distance from top of

plunger shaft to top of dust cover boss shouldbe as listed. Adjust by bending throttle con-nector rod.

O-With choke valve closed, tighten fast idle screwon high step of fast idle cam until the clear-ance listed exists between throttle valve andcarburetor bore.

@-With throttle wide open, there should be theclearance listed between upper edge of chokevalve and inner wall of air horn. Adjust bybending unloader lip on throttle shaft lever.

FloatLevel

Fig. O-YF float level.

FloatDrop

IdleScrewTurnsOpen

PumpTravelSett ing

FastIdle

Sett ing

@ None

2 Rich

None

None

@-With bowl cover held upright, distance betweenfree end of float and bowl cover should be aslisted. Adjust by bending stop tabs on floatarm.

@-With throttle valve closed, press down on upperend of diaphragm shaft until it reaches bottom.Metering rod arm should now contact pumplifter link at outer end and nearest springs.Adjust by bending pump connector link at lowerangle.

@-With choke held wide open, l ip of fast id lecam should contact boss on body casting. Ad-just by bending at offset portion of chokeconnector link.

TLOAT SHOULD JUSI TOUCH GAUGEAT THIS POIlIT

Fis. @-WCD float level.

Fig. @-WGD float level. With solid needle B%",with spring loaded needle #".

@-With throttle valves closed, distance from dustcover boss to top of plunger shaft should beas listed. Adjust by bending throttle connectorrod.

@-Hold choke valve closed, then close throttle.There should now be the clearance listed be-tween throttle valve and carburetor bore. Adjustby bending choke connector rod.

@-With throttle valves wide open, close chokevalve as far as possible without forcing. Thereshould now be the clearance listed betweenupper edge of choke valve and inner wall ofair horn. Adjust by bending arm on choke tr iptever.

Clutch, Tronsmission qnd Trqnsfer Cqse

CLUTCH PEDAL, ADJUSTJeeps

To adjust the clutch pedal free travel,which should be 7r/2" ,lengthen or shortenthe clutch control cable as required.

Station Wagons (Ercept "6-226"1To adjust clutch pedal free travel,

which should be 1", turn the threadedconnection between the clutch control

lever and the clutch control tube leveras required to obtain the desired result.

"6-226"To adjust the clutch free pedal travel

on these models, loosen the two Iock nutson the pedal adjusting rod. Turn thenuts forward to increase or backwardto decrease the free travel. After pedalfree travel of 1" is obtained, tightenboth lock nuts against the adjustingtrunnion, being careful not to changethe adjustment.

c[uTcH, REPTACEBoth the Auburn and Rockford

clutches, Figs. 1 arrd 2, are used. Theyare of the single plate, dry disc type,the difference between them being thatthe Auburn clutch has three springswhile the Rockford clutch has six.

When it becomes necessary to replacethe clutch assembly or just the drivendisc, follow the procedure outlined forremoving the transmission or transmis-sion and transfer case from the vehicle.

tt23

WILTYS- JEEPNote that labor uill' be satseil on allmodels encept "6-226" il the engi'ne isremoueil from the cft,ossis without thebell housing. Then remove the clutchfrom the flywheel.

models, which are equippedwith a split bell housing, it is advisableto disconnect both the front and rearpropeller shafts, pull the transmissionand transfer case to the rear sufficientlyto clear the shaft from the clutch. Re-move the bottom Dan from the bellhousing and remove-the clutch from theflywheel with the engine still in thevehicle.

If only a new driven disc is to be in-stalled, mark both the pressure plateand flywheel so that the assembly maybe installed in the same position to main-tain clutch balance. Wh-en removing theclutch from the flywheel, loosen the at-taching screws a turn or two at a timein progression to prevent distortion ofthe clutch bracket (cover).

Installation is made in the reverseorder, being sure to turn the screws alittle at a time in progression until allare tight. When installation is complete,adjust the clutch pedal free travel asoutlined above.

TRANSMISSION,REPTACE

Jeeps & 4-Wheel DriveStation Wagons

1. Remove front and rear propellershafts.

2. If vehicle is equipped with a powertake-off. disconnect transfer caseend of power take-off drive shaft.

PftESSUREcL #[+]'i.riliiBEAil(fT.'

Fig. I Loyout of Rotkford Glulch pottg

3. Disconnect speedometer cable attransfer case.

4. Disconnect brake cable.5, Support transmission and engine

with jacks.6. Remove nuts holding rear mounting

to frame crossmember.?. Remove transfer case snubbing rub-

ber bolt nut at crossmember.8. Remove shift lever or remote control

rods.9. Disconnect clutch release cable at

bell crank at yoke end.10. Remove floor board inspection plate.11. Renrove transfer case shift lever

pivot pin screw.12. Remove transfer case shift lever

pivot pin and remove levers. ff ve-hicle is equipped with power take-

off, remove shift lever plate screwsand lift out lever,Remove frame center crossmember.Remove bolts holding transmissionto bell housing.Force transmission to right to dis-engage clutch control lever tube balljoint.Lower jacks under engine and trans-mission and slide transmission andtransfer case toward rear of vehicleuntil clutch shaft clears bell housing.

Separate Transmission FromTransfer Case

Drain lubricant from both units.Remove five screws from coveron rear face of transfer case (ifequipped with power take-off, re-move power take-off shift housing).Remove transfer case main drivegear from rear end of transmissionmainshaft.Remove shift tower from transmis-sion.fn the absence of a transmissionmainshaft retaining plate, loop apiece of wire around the mainshaftjust bach of the second speed gear,twist the wire and attach one endto right hand front cover screw andthe other end to left hand coverscrew.Draw wire tightly to prevent main-shaft from pulling out of transmis-sion case when transfer case is re-moved.Separate the two housings, usingcare to see that the transmissionmainshaft bearing, which bears inboth housings, remains in the trans-mrsslon case.

8. Reverse the removal procedure toattach the transmission to the trans-fer case and install the assembly inthe vehicle.

Two-Wheel Drive Station WagonsThe following outline covers removal

of transmission and overdrive. If not so

16.

13.L4.

15.

1.,

4.

5.

3.

6.

t .

l ig.2 Loyout of Auburn clutch pqrts

WIttYS JEEP

equipped, disregard operations pertain-ing to overdrive.

1. Disconnect remote control rods attransmission.

2. Disconnect two wires from overdrivesolenoid. Tag wires and terminalsto assure correct assemblg.

3. Disconnect two wires at overdriverail switch. Tag wi,res and' termi'nalsto assure comect assemblg.

Fig. 3 Exploded view of lrsnsmission. Jeeps and four-wheel drive Sttrlion Wagons

Disconnect front universal joint, andspeedometer cable at transmission.Have available an ordinary cork ofcorrect size to close cable openingto prevent leakage of lubricant.Disconnect overdrive control cableand conduit.Remove rubber mounted saddle sup-port at rear end of overdrive. U3ecare not to lose spacers. Removeoverdrive governor.

5.

6.

8.

9.

10.

Place jack under flywheel bell hous-ing and raise it to support weightof housing.Remove frame cross member withrubber insulators attached.Place jack under engine to supportengine when transmisson is removed.

Thread out four screws attachingtransmission to bell housing as far

Fig. 4 Exploded view of tran3mi3sion. Two-wheel drive models

WILTYS JEEP

Fig. 5 Exploded view of ironsfer .ose. Jeeps ond four-wheel drive Stoiion Wogons

as possible and yet support weightof transmission. PuIl transmissionback to bolt heads which will pro-vide approximately 3/4 " opening be-tween the two housings and at thesame time relieve pressure on clutchrelease fork in bell housing.

11. Use a long screwdriver throughopening in side of bell housing to pryclutch release fork from engage-ment with clutch release bearingcarrrer,

12. Complete removal of four transmis-sion attaching screws and pull trans-mission back until clutch shaftclears bell housing and remove theassembly with release bearing car-rier attached.

TRANSMISSION REPAIRSFour Wheel Drive, Fig. 3

1. Drain lubricant from case and cleancase with a suitable solvent.

If transfer case is attached, removeits rear cover.If equipped with a power take-off,remove the shift unit which reDlacesthe cover.

4. Remove transfer case main drivegear.Remove transmission cover.Loop a piece of wire around main-shaft directly back of mainshaftsecond speed gear. Twist wire andattach one end to right hand frontcover screw and other end to leftfront screw. Draw wire tightly toprevent mainshaft from pulling outof transmission case when transfercase is removed. Should mainshaftcome out, synchronizer parts willdrop into bottom of case.Support transfer case and with arawhide mallet or brass drift andhammer, tap lightly on end of trans-mission mainshaft to separate thetwo units. The transmission main-shaft bearing should slide out of

transfer case and remain in trans-mlssron.

8. Remove drive gear bearing retainer.9. Remove Iock plate and drive coun-

tershaft out through rear.10. Remove mainshaft rear bearing

adapter.11. Remove mainshaft and gear as-

sembly through transfer case open-rhq

12. Remove countershaft gearset andthrust washers, noting position ofwashers.

13. Drive reverse idler shaft out rear-ward and lift out gear.

Assembly NotesReverse the order of the above proce-

dure to assemble the transmission, beingsure to observe the following precautions:

The countershaft gearset should havefrom .072" to .018" end play when as-sembled in the case. This clearance isobtained by selec'uive thickness of therear steel thrust washer. which is avail-

,

3.

o.

b.

WILLYS JEEPable in two thicknesses. Assemble thelarger bronze washer at the front of thecase with the lip entered in the slot inthe case. The bronze faced steel washergoes next to the gear at the rear end,and the steel washer next to the case.tlse a loading sleeve to assemble thecountershaft roller bearings.

Tvcf Wheel Drive, Fig. 41. Remove cover, front flange and snap

rings from pinion bearing.2. Use puller to remove pinion bearing,

using a suitable synchronizer ringprotector to take up the thrust andprevent possible damag:e to thesynchronizer.

3. Pull off the companion flange, re-move the rear bearing retainer andoil seal. and slide the speedometerdrive gear off the shaft.

4. Mark the synchronizer blocker rings,gear and sleeve so that these partsmay be reassembled in their originalposition.

5. Raise the drive pinion over the coun-tershaft gear, pull the mainshaft andbearing rearward and remove thedrive gear from the case.

6. Cock the mainshaft to the side asfar as possible, disengage and re-move the shift forks.

7. Release the mainshaft front snapring. Grasp the mainshaft parts andslide the shaft through these partsand out through the rear.

8. Remove the lock plate and drive thecountershaft out rearward.

9, Lift out the cluster gear and wash-ers, noting the position of theseparts.

10. Drive out the shaft and lift out thereverse idler gear.

11. Remove the shift shaft locating pinsand take out the shift levers andshafts and oil seals.

12. Assembly may be made in the re-verse order, being sure to use newgaskets and oil seals.

TRANSFER. CASEFour Wheel Drive, Fig. 5

fn removing the transfer case, followthe procedure outlined under transmis-sion removal. Then dismantle the caseas follows:

1. Remove propeller shaft flange,brake assembly and linkage.

2. Remove lower cover.3. Remove lock plate.4. Drive intermediate shaft to rear of

case, being careful not to lose thrustwashers.

5. Remove intermediate gear, thrustwashers and roller bearings throughbottom of case.

6. Shift front wheel drive to engagedposition (shaft forward) and removepoppet plugs, springs and balls onboth sides of output bearing cap.

?. Remove output bearing cap togetherwith the universal joint end yoke,clirtch shaft, bearing, clutch gear,folk and shift rod. IJse care not tolose the interlock.

8, Remove output shaft snap ring andthrust washer.

9. Use a rawhide mallet to driveagainst the front end of the main-shaft to start the rear bearing fromthe case. As the shaft is removed,the gears will remain in the caseand can be taken out through thebottom, also the snap ring andthrust washer.

10. Remove set screw in sliding gearshift fork and take out the shift rod.

11. Disassemble the front and rear bear-ing caps as required.

Assembly NotesReverse the order of the above proce-

dure to assemble the transfer case. Butwhen rear bearing cap assembly is in-stalled, check the end movement of themainshaft which determines the adjust-ment of the tapered roller bearings. Forcorrect bearing adjustment, the shaf,tshould have from .004" to.008" end play.Adjustment is made by selective shiminstallation between the cap and case.Shims .003", .010" and .031" thicknessesare available for this adjustment, Do notinstall the rear cap oil seal until thebearings are properly adjusted.

GEARSHIFT, ADJUSTRemote Control Models

To make an adjustment, shift the handcontrol lever to its neutral position. Alignthe pin holes in the levers at the bottomof the main shifting rod to hold themin their neutral positions. Disconnect thecontrol rods from the levers at the trans-mission and place the transmission leversin neutral. Finally, adjust the length ofthe control rods so that they will justslip into their respective levers on thetransmission without moving the leversfrom their neutral positions.

Service NoteDi,fficult shilting on tuo-usheel il,riue

utdldtg uehicles and, statcon wagons nLoAbe due to i,mproper instttllation of tkesecond, anil high shilt roil on the sltiftl,etser.

The sh,i,ft leuer, mounted, on the lowerend, ol the remote control, shift sh,aIt, isprouided nnith tuo holes. The shilt roil,sh,oulil ba placeil in the outer hole of theleuer on sin cglind,er models anil, in tlteinner hole on four cglind,er moilels.

Reor Axle, "Liye" Front Axle ond BrqkesRefer To Hydraulic Brakes Chapter For Brake Adjustments

R,EAR, AXLEThis rear axle is of the semi-floating,

hotchkiss drive type. The drive pinion isthe over-hung type, mounted on pre-loaded taper roller bearings. Sealing ofthe pinion shaft is accomplished at thefront end by a spring-loaded leather sealbearing on the companio_n-flange, whichis splined and secured to the pinion shaftby a nut, fig. 1.

Axle Shaft, RemoveTo remove an axle shaft, jack up the

wheel and pull off the hub and brakedrum. Block the brake nedal in such amanner that it cannot be- depressed. Dis-connect the hydraulic brake line fromthe wheel cylinder. Remove the mountingscrews and take off the outer oil seal,shims and brake support. The shaft andbearing may then be pulled out of the

housing. The inner oil seal may be re-moved at this time.

Axle Shaft, InstallReplace the shaft and bearings in the

reverse order. If the old parts are re-placed and the shims have not beendisturbed, the end play should be correctwhen the parts are assembled. Ilowever,if a new axle shaft, bearing, differentialcarrier or housing has been installed, itwill be necessary to check the end play.

Arle Shaft End Play, AdjustAxle shaft end play can be checked

when all parts have been replaced ex-cept the wheel and hub. To make thecheck, rap each axle shaft after the nutsare tight to be sure the bearing cupsare seated. Then mount a dial indicatoron the axle housing with its contact

button touching the end of the shaft.Work the shaft in and out by hand andnote the reading on the indicator. If anadjustment is necessary, remove the oilseal and brake support and add or re-move shims as required to bring the endplay to .001" to .005".

When making this adjustment, anequal thickness of shims should be re-moved or added on each side of the axlehousing to maintain the central positionof the axle shafts.

Rear Axle Assembly, Replace

Inasmuch as the axle tubes are pressedinto the differential carrier to form aone-piece housing, the rear axle assemblymust be rernoved from the chassis whenit becomes necessary to overhaul theunit.

1. Raise vehicle from floor and support

WIftYS JEEP

with stand jacks under frame siderails.Remove rear wheels.Split rear universal joint.Disconnect parking brake cable (ifequipped) from opelating lever andfrom brake backing plates.Disconnect hydraulic brake line con-nection at rear axle housing.Loosen and move shock absorbersout of the way.While supporting axle housing withhydraulic jack, remove spring clipsand lower axle assembly to the floor.Reverse the foregoing procedure toinstall the rear axle assembly, beingsure to bleed the bral{e system whenthe installation is completed.

Differential Carrier, Disassemble1. Remove axle shafts as outlined pre-

viously. Axle shafts may be pulledout only far enough to clear differ-ential side gears.

2. Drain lubricant and remove rearcover.Make sure differential side bedringcaps and axle housing are marked,then remove the side bearing caps.Pry differential from housing.Remove side bearing cups.Pull off side bearings and adjustingshims, tagging the shims for identi-fication on reassembly,Unfasten ring gear from case.Drive out differential pinion shaftpin and pull out the shaft, pinionsand side gears.Hold companion flange from turningand remove flange nut.

Fig. t Exploded view of reor oxle ossembly. Al l Models

10. PuIl flange from pinion shaft.11. Remove pinion from carrier by tap-

ping on front end with soft hammer.12. Remove pinion shaft bearing oil seal

and bearings from carrier, keepingseparate the shim pack at eachbearing.

Pinion & Bearings, ReplaceIf the original ring gear and pinion

are being used in the original carrier,use the original shim packs at each

bearing, Fig.2. If a new pinion or differ-ential carrier is installed, note the mark-ings on the end of the pinion gear a1don the differential carrier to obtain thecorrect thickness of shimming to be usedwith these parts from your supplier. Theshims behind the rear bearing estab-Iishes the correct pinion depth.

1, Press the rear pinion bearing cupin the housing with the proper thick-ness of shims. Press the rear pinionbearing on the shaft.

2. Install the front bearing cup andshims, and front bearing.

3. Install the companion flange and,while holding the flange from turn-ing, tighten the nut to a torque loadof 200-220 Ib. ft.

4, Check the pinion bearing pre-loadwith a spring scale and heavY cordwlapped around the comPanionflange. Pull on the spring scale. Thetorque required to rotate the pinionis 10-30 inch lbs. If not within theseIimits, add or remove shims frombehind the front bearing to obtainthe proper pre-load.

5, Remove the companion flange andinstall a new oil seal (well soaked).Reinstall the companion flange andtighten the nut.

Ring Gear, Replace1. Install guide pins in every other hole

in the ring gear. These Pins can bemade from 71/2" long capscrewswith heads cut off and ends slotted.

2. Make sure back face of ring gearand face of case are free of dirt and

23.4.

o.

6.

7.

8.

4.o.6.

a.

8.

3.

9.Fig. 2 Reor oxle odiustments. All models

WILLYS JEEP

Fig. 3 "Live" fronl sxle. Jeeps ond four-wheel drive Stqtion Wogons

burrs and slip gear over pilot diam-eter of case.

3. Install every other ring gear bolt.Draw them up evenly and snuglYso ring gear face is flush with case.

4. Remove guide pins and install re-maining bolts.

Different ial Carr ier, AssembleThe differential bearings are adjusted

by shims, Fig. 2. These shims also estab-Iish the ring gear position with theninion. Therefore, backlash must bechecked whenever a bearing adjustmentis made.

The correct bearing adjustment is onewhich will provide a .008" pinch fit whenthe differential unit is assembled intothe carrier. To make the adjustment,install the bearing cones without shimsand place the assembly in the housingwith the bearing cups. I'orce the unitto one side and check the clearance be-tween the bearing cup and differentialcase with a feeler gauge. When the clear-ance is determined, select shims of thisamount plus .008" extra to establish theproper pre-load.

Remove the differential bearings againand divide the shims into two packs ofeoual thickness and install on each sidearid replace the bearings. Reinstall theunit in the carrier. This operation ismade easier by cocking the bearing cupsslightly when the differential is placedin the housing and then tapping themIightly with a mallet. IIowever, when in-stallinE the differential in the housing,

be sure the ring gear teeth mesh withthe pinion teeth before tapping the bear-ings in place.

After the bearing cups are firmly inplace, install the bearing caps. Thebearing caps and gasket surface of thehousing are marked with a horizontalnumeral and on the other side by a ver-tical numeral. The position of the nu-merals should correspond when rein-stalling the bearing caps.

Ring Gear & Pinion Backlash,Adiust

Mount a backlash gauge indicator onthe carrier and start checking for thecorrect backlash between the ring gearand ninion. If the backlash is not withinthe limits of .004" to .009", it will benecessary to change the arrangement ofthe shims back of the bearings. Makecorrections in backlash, as described forthis type axle in the Rear Anle Chapter,bearing in mind that shims removedfrom one side must be installed on theopposite side so that the total shim thick-n-ess of the right and left side will remairiunchanged, and the bearing adjustmentundisturbed.

Gear Tooth Contact Pattern

Allowable variations in the caruier ordrive pinion may cause the pinicin to betoo far in or out even when shimmedproperly. Thus, the tooth contact mustbe tested and corrected as necessary orthe gears may be noisy.

Paint the ring gear teeth with a lightcoating of red lead, white lead or prus-sian bfue. Revolve the gears and observethe contact, referring to the itlustrationsshown in t}ne Rear Anle Chapter for thisoperation.

lnstal lat ion in Vehic le

To jnstall the axle under the vehicle'have the end of the vehicle securely sup-ported with a chain hoist or a supportunder the frame just ahead of the rearsprings. Place the axle assembly in posi-tion and raise it so the spring clips andfront spring bolts may be installed. Con-nect the brake line hose at the frame,install lock clip and attach brake line.Connect the propeller shaft at the rearuniversal joint. The wheels may then beinstalled and the vehicle lowered to thefloor. Bleed the brakes to remove anyair from the lines.

,,LIVE,, FRONT AXLEFour-Wheel Drive Models, Fig. 3

The front axle on these models is alive driving unit with hypoid drivinggears and spherical steering knucklesmounted on pivot Pins which ride ontapered roller bearings for ease of steer-ing. The drive is of the full-floating typethrough axle shafts built integrally withconstant velocity universal joints whichrevolve in the steering knuckles.

WILTYS JEEP

Fig. 4 Bendix typo qxle rhoft ondunlverool loint. For "live" front dxles

Fig. 5 Rzeppq type orle ohoft onduniversol iolnt. For "llve" front arles

Front Axle ServiceThe differential is mounted in a hous-

ing similar to that used in the rear axleexcept that the pinion shaft faces towardthe rear instead of to the front and tothe right of the center of the axle. Thistlesign allows the placing of the frontpropeller shaft along the right side of theengine oil pan to avoid reducing roadclearance under the engine.

The axle is of the full floating typeand the axle shafts can be removed with-out dismantling the steering knucklehousing.

Overhaul of this axle unit is the sameas the rear axle.

Service Note (Arle Shafts).4. change in design of the front axle

on four-wheel drive vehicles was placedin productioE effective with the follow-ing serial numbers:

No. 37549 on CJ-3ANo. 440?0 on 4WDNo. 14284 on 4x463fn the new design the front axle shaft

outer splined end floats in the wheeldriving flange and is not retained by anut and lockwasher as originally used.With this construction it is no longernecessary to install shims between thedriving flange and wheel hub to providethe correct end float of the axle shaftuniversal joint.

The new construction, when usingthe Bendix type axle shaft, is shownin F ig. 4. Note that the end float of the

Bendix type joint is predetermined inmanufacture by the position and flangethickness of the bushing and thrustwasher. These parts are so positionedand of the correct thickness to provide.088" maximum end float of the universaljoint to operate at the centerline of thespindle pivot pins. With the correct jointend float controlled by the bushingflange and thrust washer, it is no longernecessary to install shims between thedriving flange and wheel hub, a gasketonly being used.

The new type Bendix axle shaft anduniversal joint may be readily installedin an old type axle by installing the newtype flanged bushing. When this is done,discard the shims previously installedbetween the flange and hub, installing agasket only. The flanged bushing re-quires no reaming and is so designedthat when it is pressed into the spindleit will be compressed to provide correctrunning clearance. Coat the inner surfaceof the bushing with chassis grease beforeinstalling the spindle.

The axle construction is similar forinstallation of the Rzeppa joint, Fig. 5.The thrust washer is not necessary al-though it is installed in all axles to allowinstallation of the Bendix type shaft ifso desired. As the thrust washer is noteffective, a snap ring is installed at theouter end of the shaft to control endfloat.

Steering Knuckle Pivot PinsWhen reinstalling a steering knuckle,

sufficient shims must be installed under

the bearing caps so the proper tensionwill be obtained on the bearings. Theshims are available in thicknesses of.003", .005", .010" and .030,".

Install one each of the shims over thestuds on the steering knuckle -at thetop and bottom. Install the bearing caps,lock washers and nuts and tilhten se-curely. Check the tension of the bearingsby hooking a spring scale in the hole inthe arm for the tie rod socket. The loadshould be 6-9 lbs. without the oil sealin position and is secured by adding orremoving shims as required. Make surethere are the same thickness of shimsbetween the upper cap and the knuckleas between the lower cap and knuckle.

Service Note (Lower Shims)On models CJ-3A, 479-4WD and 4x473,

.058" was added to the bottom face ofthe king pin boss on the steeringknuckles. This eliminated the shims forthe lower kingpin bearing and the ad-justment of the bearing is now made byshims at the top only.

BRAKE MASTERCYIINDER,, REPIACE

To remove the master cylinder, dis-connect the fluid lines and .stop lightwires from the cylinder. Unfasten thecylinder from its mounting. Remove theeye bolt from the shaft and drop thecylinder from its mounting.

Front End ond Steering SectionCAMBER & CASTER

Two-Wheet Drive Station WagonsCamber is adjusted by adding or re-

moving shims as required from behindthe upper control arm frame bracket,F ig. 1.

Caster is controlled by the relation-ship between the position of the frontspring and its location in the framecross member channel. If caster is out,examine the Suspension for worn ordamaged parts.

TOE.IN, ADJUSTTwo-Wheel Drive Station Wagons

Load the front end of the vehicle byweights or persons so that the frontspring main leaf is flat. F latness of thefront spring main leaf may be checkedby holding a straight edge or stringbelow the main leaf, and parallel with it.

Roll the vehicle backward and for-ward so that all parts will attain a nor-mal position. With suitable trams org:auge, measure the distance between

the wheels at the rear and then at thefront. These measured distances shouldbe equal (for zero toe-in).

ff the distances are not equal, read-just the tie rods as required to makethe distance equal.

When the load is removed from thefront of the vehicle, it will be foundthat the wheels will attain a slighttoe-in, ranging from L/x to t7 in., de-pending upon the arch of the frontspring. This is normal and will givesatisfactory results in respect to tirewear and proper handling of the ve-hicle.

WITLYS JEEP

HORN BUTTON OR R,INGRemove the horn button or steering

wheel hub cover by turning it about 7eturn to the left and disengaging.

STEERING WHEELAfter removing the horn button and

ring, use a suitable puller to pull off thesteering wheel.

STEERING GEAR, REPLACEJeeps & Station Wagons

It is necessary to pass the steeringgear down through the floor pan. Theprocedure is as follows:

1. Remove left front fender on CJ-2A.2. Disconnect remote control rods from

levers on steering column if equip-ped with steering post shift.

3. Remove horn button and steeringwheel.

4. Remove steering post bracket at in-strument panel.

5. Remove steering post hand lever.6. Remove exhaust pipe from manifold.7. Remove steering column cover plate

on toe board.8. Remove two screws attaching re-

mote control housing to steering col-umn.

9. Remove horn wire contact brush(CJ-2A) or disconnect horn wire.

10. Remove remote control gearshift as-sembly down through floor pan.

11, Remove pitman arm from steeringgear.

12. Unfasten steering gear from frameand bring it down through the floorpan and over the outside of theframe side rail.

STEERING GEAR REPAIRSThis steering gear, F ig. 2, is the cam

and twin lever type in which the cam is

f i : i i n : i , ! t r : !! : I r : r

' l i i.i tl,,,,il "i;i rf 1,r1,i,.! i i" I I I tri ;t:, I I

Fig. I Front Suspension. Two-Wheel Drive Slotion Wogons

| - f ronl spr ing l ! - lv6 pin bushing

7 - Nut 18 - Kingpin! - fi1qjns brockel 19 - Knuckle

3?.

! - (enfy6l gy6 l t -

(6nf1ql qrm pin3 - Comber shims 14 - Greose f i t t ing4 - Rubber bushing 15 - Knuckle suppor l5 - Control qrm wosher l5 - Knuckle beor ing6 - Lock wqsher l / - lgsl ing wosher

9 - Cofier pinlO - Nutl l -Dust seol

20 - Greqse filtingll - tapq6sion plug22 - Knuckle bushing

23 - Thrust beoring24 - Kingpin lock pin25 - Greose fitting26 - Spring bushing27 - Bol t lock28 - Pivot boh29 - Pin wosher!Q - f,ullgs bushing3l -Shock

qbsorber32 - Cotter pin

FRONT END REPAIRSTwo-Wheel Drive Station Wagons

Kingpins & BushingsThe following text applies to earlier

models insofar as this operation is con-cerned.

1. Remove wheel hub and dust caps.2. Take off wheel and hub, bearings

and oil seal.3. Disconnect hydraulic brake tube

and remove brake backing plate withbrake assembly attached.

4. Drive out kingPin lock Pin.5. Use a sharp drift to remove the

kingpin lower expansion Plug.6. Use a brass drift to drive the king-

pin up until the upper needle bearingis removed,

7. Use a brass drift to drive the king-pin out through the bottom.

8. Remove the bushing from the lowerpart of the spindle.

Assembly is the reverse of the above.When reaming the bushing to size, usea pilot type reamer to be sure that thebushing is square with the upper needlebearing. Examine the ball thrust bear-

ing and replace it if worn or damaged.Do not overlook bleeding the brakes.

Steering Knuckle SupportsShould it be necessary to disassemble

the front suspension, be sure that thesteering knuckle supports are reinstalledon the proper side. The left support willinterchange with the right but the wheelcamber will be incorrect, resulting inunstable steering. The supports havethe part number on the forging for iden-tification-641026 left side, 641027 rightside. Later production parts may beidentifled by the letter L for left andR for righl.

When mounting the upper controlarm pin bushing in the steering knucklesupport, tighten it to 175 lbs. ft. torque.Centralize the control arm over theknuckle support before starting tothread the pivot pin through the sup-port. This is necessary to provide theproper caster effect and equal clearanceat each side of the support for the rub-ber dust seals. Also for the same rea-sons centralize t}:le spring eye in thelower end of the knuckle support be-fore starting the spring pivot bolt. Fig.2 Sleering geor odiustments

WITLYS JEEPmounted on ball bearings and the levershaft turns on steel backed bronzebushings.

As the cam is turned by the wheeltube, the follower studs are pulled alongthe cam groove, causing the lever armto rotate the lever shaft. The groove inthe cam is cut shallower in the straight-ahead driving position to provide closeradjustment between the studs and thecam where most of the steering actionoccurs,

Cam End Play, Adjust1. Free the steering gear of all load by

disconnecting the drag link andloosening the steering column braces.

Loosen the lock nut adjusting screwin the side cover to free the studsin the cam groove.

Remove the upper cover stud nutsand raise the housing upper coverto permit removal of the adjustingshims, which are .002", .003" and.010" thickness.

4. Clip and remove one thin shim,tighten down the cover and checkthe adjustment. There should be aslight drag but the steering wheelshould turn freely with the thumband forefinger lightly gripping therim. If necessary, remove or re-place shims until the adjustment iscorrect.

Lever Shaft Backlash, Adjust1. Centralize the steering gear by turn-

ing the wheel all the way to theright. Then, starting from this point,count the number of turns requiredto reach end of travel to the left.Turn the wheel back half this num-ber of turns to the mid-position.

2. I'ighten the side cover adjustingscrew until a very slight drag is feltthrough the mid-position when turn-ing the steering wheel slowly fromone side to the other. The gearshould not bind in any position buta slight drag should be felt in themid-position only.

3. After proper adjustment is secured,tighten the lock nut and give thegear a final check for binding.

t

3.