Jeep® CJ Rebuilder’s Manual: 1972 to 1986

Jeep® manual Index:

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Index

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

Accessories, 552?573
Adapter plate, 82, 234?236
Advance Adapters, 81, 88, 540
conversion kits, 88
motor mounts, 94
Saginaw steering retrofit kit, 376
steering column, 408?411
transmission adapters, 82?87,
91-97
Air compressor, 444, 573
Air intake and filtration, engine, 488
Alternator, 437
Premier Power Welder, 554
Anti-friction bearings, 579-585
Anti-rattle springs, 282
ARB air locker, 282, 283, 288, 290, 291, 297, 571-573
Axles
front, 211
axle shaft U-joint and shaft installation, 250
disassembly, 213?225
disc brake upgrade, 384?391
rebuilding, 299?311
steering knuckle service, 241
torque settings, 351
general, 210
housing
ventilation, 370, 558
ratio, noting, 13
rear, 258
aftermarket locker, 263?271
air locker, 288-298
AMC Model 20, 274-308
Dana 44, 261-273
full-floating rear axle shaft conversion, 271?273
service (rebuilding) and upgrades, 258-308
tapered axle shafts and hubs, 274, 298?308
torque settings, 321
vent, 558
removal, 19-21
seal, installation of, 255,273, 299-305
shaft installation, 250?256
shims, 211, 223-230, 234-237, 264, 293,
subletting axle work, 211

B

Barrett Engineering, Inc., 448
Battery, 444, 448
Battery box, 330
Beachwood Canvas Works, 441
Bearing caps
axle, 220, 234, 236, 261, 266, 277
transfer case, 129, 141, 160, 161, 181-184, 196
Bearing cups
axle, 212, 222, 227-229, 232-234, 260, 265, 272, 276-279, 281-294, 301, 304, 318
pinion, 318
transfer case, 138, 144, 150-152, 170, 173, 182-184, 187
wheel, 385-386, 399-402
Bearing installation tool, 226
Bearings
anti-friction, 578?585
camshaft (See Camshaft)
engine or "sliding," 578
failure, causes of, 582
fundamentals, 578
service precautions and details, 585
tapered roller bearings, 583
throwout (See Throwout bearing)
wheel, 394?407
Bellcrank, 366-367
Bellhousing, 82, 86-87, 91, 95, 97, 101-102, 114-120
adapter plate, transmission, 79, 84-87
Bench Mule, 19, 220, 224
Bendix Hydrovac brake booster unit, 426
BesTop
Seat installation, 564-567
Super Top, 561
Body, 324?328
modifications and restoration, 349?354
tub disassembly, 9?14
Borg-Warner transmissions,
60-61
See also Transmission
Brake backing plate, 216, 256, 260, 271-275, 302
Brake fluid, 380, 383
Brake system, 379
adjustment tips, 382-383
calipers, 273, 428, 430
disc,
conversion 384?393
master cylinder check valves, removal of, 392
drum, 294, 327, 346, 347, 416
disassembly, 257
11-inch drum brake conversion, 419?420
service, 380-382
emergency/parking brake adjustment, 418
hoses, lines, and tubing, 368-369, 376-381, 419-431
flex, 428
lights, 459
master cylinders, 422-425
check valves, removal of, 392
metering, 425, 446
pressure differential, 432
proportioning, 426, 431-433
pedal, 382-383, 424, 426, 427, 432
pipe, 382, 392, 409, 419-429
power/vacuum assist, 383, 385, 425, 426
pressure differential, 432
Brake system (continued)
proportioning and metering,
431?432
service, 379-381
upgrades, 379
disc brake, 418?426
hydraulic system, 425-431
wheel cylinders, 380-383,
407-409, 422-423, 426
Breaker point set, 452?459
Buick V-6, 574
Bumper, front, 329
Bushings
flywheel pilot, 115, 117
suspension, 343-346

C

Cam tube, 367
Camshaft, 27, 35
bearings
installation, 34
timing marks, 38
Caps, rod
See Rods and pistons
Carburetor
Adjustment, ?YF' one barrel, 487
Carter one-barrel, 474?486
cleaning, 475, 479, 489, 497, 506-508
float measurements,
?BBD', 513
?YF', 483-485
installation (?BBD' two-barrel), 518
jet, 480, 482, 509
needle seats, 482-485, 494, 496, 499, 510, 517
rebuild kits, 4725, 482, 488, 491, 494, 496, 504, 509, 512, 516
throttle linkage, 486, 514
Centerforce clutch assembly, 91, 112-114, 119-120
Chassis, 16?21, 591
Choke, 474, 475, 487, 491,
494-497, 506, 516-519
Classic Tube & Performance, 427, 432, 433
Cleaning,
bearings, 585
carburetor, 475, 479, 489, 497, 506-508
transfer case, 137, 158
Clutch, 586
adjustment, 119
Centerforce clutch assembly, 91, 112-114, 119-120
disc, 112-113, 115, 117, 119, 120
housing (See Bellhousing)
installation, 239?243
linkage
disassembly, 23?24
upgrades, 244?247
master cylinder, 179
Midway/Centerforce clutch assembly, 237?243
pedal, 15, 245, 445
pressure plate, 36, 239, 241, 242
service and replacement,
112?117
shaft, 65, 66, 74-78
sleeve, 64-65, 71, 74, 78, 80
types, 113
Clutch alignment tool, 117
Connecting rods
See Rods and pistons
Cooling system, 50, 51, 53, 56, 521, 541
Corner reinforcement plates, 441
Counter gear, 88
Countershaft, 61, 67-70, 77
Crankcase, 48, 59, 490, 491
breather, 155
closed crankcase design, 472, 494
oil, filling with, 41, 523
Crankshaft
balancing, 41
flywheel, 41, 50, 82, 91, 113-117, 121
polishing, 31
vibration dampener/pulley, 43-46, 522, 524
Cylinder block
See Engine block
Cylinder bores, 32, 34
rod and piston installation, 38
Cylinder heads, 40, 51, 527
bolts, 58?59, 94?95, 147?148, 172
machine work, 32-33
Cylinders, 30

D

Damper,
crankshaft, 41, 46, 48, 56, 522, 524
steering, 375, 553
Dana axles, 210, 212, 226, 234, 238, 258, 261-273, 274, 311, 319, 321
cross-joint axle shaft, 250-259
cross-type U-joint, 250-255
Dana 44, 261-273
swap, 257
disc brakes for, 384-391
Spicer 44 rear axle, 261-273
swap, 257
Dial indicator, 127, 142, 153, 186, 190, 212, 226, 238, 265, 267, 276, 289, 292, 296, 306
Differential carrier, 225, 233, 238, 261, 264-265, 277-278
Disassembling the Jeep, 1?21
Disc brakes
See Brake system
Distributor,
See Ignition distributor assembly
Dog harnesses, 559
Drag link, 367
Driveshaft
removal, 6
upgrade for suspension lift,
341-342
Drum brakes. See Brake system
Dust seal, spring-loaded
See Spring-loaded dust seal

E

Electrical system, 437?450,
463-470
Electronic fuel injection, conversion, 490, 519-543
Emergency brake,
See Brake system
Emissions requirements, 487, 490, 496, 520, 542-544
Engine, 23?57
air intake and filtration, 488
block (See Engine block)
break-in procedure, new/rebuilt engine, 547?549
crossmember
rebuilding, 336?338
machine work, 30-41
overview, 24?28
rebuilding, 29?41
cooling system for rebuilt engine, 50
removing, 7-8
swaps, 28
timing, 132, 472
V-8, 27, 49, 451, 470, 488, 544
Engine block
accessories, 50-54
boring, 31
cleaning, 32
machine work, 31, 34, 37
oil filters/check valve, 31, 34, 36
remanufactured, 42-49
Engine machine work, 30-41
Exhaust manifold, 49, 525
Exhaust system, 544?549
Exhaust valves, 32, 33, 48
Exterior trim, 587-588

F

F-134 four cylinder engine, 24-25, 452, 472, 574
4WD Hardware, Inc., 232, 438, 441, 445, 559, 586, 588, 589
Fan, 50-52, 55, 521
clutch, 50, 52, 55, 521
electric, 50
Filtration, air, 488-489
Flaming River steering column, 377
Float bowl, carburetor, 475-476, 479,
Floorpan, 326-327
Flywheel
balancing, 41
installation, 114-115
Frame, 325, 328-336,
bending, 356
crossmember
building, 336?338
measurement methods, 363-364
repairs, 328-339
Freeze plugs, installation of, 39
Front axle. See Axles
Front clip, removal, 9-12
Front core support, 9, 12
Fuel injection, 490, 519-543
Fuel system, 472-473, 529-541
(See Carburetor, see also Fuel Injection)
line and hose, 473, 529-340
pump, 472, 522, 532, 540
Full-floating rear axle shaft conversion, 271-273
Fuse block, 439

G

Gasoline filter, 522, 529-532
Goodridge hoses, 427, 428, 473, 554
Grant horn adapter kit, 553
Grant steering wheel, 450, 553
Ground strap, 448, 449

H

Hardware
grading and torque charts,
595-596
replacements, 441
Head bolts,
See Cylinder heads, bolts
Headlights, 440, 442
Hood latches/hinges, 563
Hood removal, 9
Horn adapter kit, 553
Hot tank, 32
Hub cap, 308

I

Idle mixture, adjusting, 487, 519
Ignition distributor, 450-451
Autolite, 452-458
MSD (multiple spark discharge) unit upgrade, 460-463
timing, 459, 523
Ignition wrenches, 452
Intake manifold, 49, 489, 525, 530, 536, 538
Buick V-6, 172?173
installation, 172?173
Intake tappets, 72, 73
exhaust valve adjustment and, 139
machine work, 79
pre-assembly preparation, 99
Intake valves, 32, 33, 48
guides, 32
inspection, 74
installation, 142
machine work, 77, 79, 80

J

Jeep Engines, 24, 29

K

Kentrol roll bar kit, 555-557

L

Light bars, 587-588
Light switch, 445
Lip seal, 81, 85, 86, 145, 255, 301
Lock plate, 63, 67, 77
Locker,
aftermarket, 263-271
air, 282, 283, 288, 290, 291, 297, 571-573
Lubrication
axle, 309, 317
breaker point, 459
engine assembly, 40, 45
transfer case, 174

M

Machine shop, 29
Machine work, engine
See Engine machine work
Magnafluxing, 32
Mainshaft, transmission, 64-67, 70, 72, 74-76
Manifolds, exhaust, 49, 525
See also Intake manifold
Maps and travel guides, 589
Mark Williams" Bench Mule, 19, 220, 224
Master cylinders
See Brake system
Mechanic"s glove, 497
Metal parts restoration, 349-362
Metering rod, carburetor, 477, 479, 481, 483, 494, 499, 502, 509, 513-515, 518
Midway/Centerforce clutch assembly, 112-114
MIG welder, 330, 338, 362
Mirrors, 569
Model 18, transfer case, 126-127
(See also Transfer case)
Model 20 (Spicer), transfer case, 87, 126-127
(See also Transfer case)
rebuild, 128-156
Mopar 3.9L V-6, 574
Motor mounts, 28
MPI, 490, 519-543
Muffler, 544-549
Multiport fuel injection, 490,
519-543

N

Needle rollers, 68, 69, 75, 138, 155, 197, 198
Novak Enterprises, 128
NV3550 transmission installation, 61, 89
NV4550 transmission,
fabrication, 103-112
transplant, 90-103

O

Oil bath air cleaners, 353-354, 489
Oil (engine)
filter, 36
CJ and Wrangler blocks and oil filters(4.2L), 35-36
V-8 engine oiling notes, 49
Oil dipstick tube, 526
Oil pan,
gasket, 44
installation, 44
Oil pressure sender, 57
Oil pump, 40, 49
installation, 42-43
Output shaft, 86, 88, 96, 97
seal, 84
Overdrive, 88, 89, 90, 281
Oxy-acetylene weld, 334, 350, 352, 353

P

Painting
body, 359
transfer case, 202
Parking brake
See Brake system
Parts, 441
resources for, 586?592
spare parts kit, 592
PCV valve, 502, 536
Pedals
brake (See Brake system)
clutch, 118, 119, 120,
Pilot bearing, 75, 87, 89, 91, 95, 113, 115, 117
Pilot bore, 115
Pinion
bearing cup, 228, 231, 318
gear, 211-212, 223, 225, 226, 228, 231, 234, 237, 239, 258, 263, 264, 284, 285, 288, 297, 318, 319
seal, 222, 263, 268
shaft, 211, 221-223, 226-231, 239, 261, 264, 268, 270, 278-281, 287-288, 291, 294, 310, 317, 320, 321
Piston ring compressor, 38
Pistons
See Rods and pistons
Pitman arm, 366, 370, 371
installation, 370,
Saginaw, 366-369, 377
Premier Power Welder alternator, 438

Q

Quadra-trac, 126-127, 203-208

R

Radiator, 50-52, 521, 534, 536
Rear axle
See Axles
Rear corner reinforcement plates, 441
Release forks, 116, 117
Resources, 586-592
Reverse idler
gear, 69
shaft, 68, 69, 77
Ring-and-pinion gearset, 211, 225, 226, 237, 258, 263, 319
setting pinion gear position, 231, 318
tooth contact, 210, 211, 212, 231, 235, 237, 238, 265, 267, 288, 296, 318, 319
Rocker arm pivots, 40
Rods and pistons
balancing, 41
engine machine work, 34
inspection, 32
main bearing shells, 37
piston rings, 491
installation, 38
polishing, 76
Roll cages, 555-558
Ross cam-and-lever steering, 366-367
Rotors, 386, 391, 399, 407, 432,

S

Saginaw steering, 366-372
steering column for, 376-377
Seals
axle, 232, 233, 250, 256, 260, 270, 273, 275, 299
output shaft, 84
pinion, 222, 263, 268
transfer case, 1227, 130, 145, 158, 170, 184, 189, 193, 195
Seat belts, 559
Shackles
See U-bolts/shackles
Sheet metal restoration, 355-362
Shift control housing, 64
Shift forks
disassembly, 64, 66, 113, 134, 136
inspection, 137, 169
installation, 80, 144, 149, 150, 151, 191-193
wear, effects of, 194
Shift levers, 5, 14, 103-112, 137
Shift rod, 134, 193, 195, 201
Shifter control housing, 63, 64, 78, 80, 104
Shims
axle (See Axles, shims)
in transfer case, 134, 135, 140-142, 153-154, 163, 166, 176, 178, 184, 188, 190
Shock absorbers, 340, 343, 348
Skid plate, 3, 4
Slave cylinder, 91, 95, 101, 116, 118, 119
Sliding gear, 126, 137, 150-151, 158
Spark plugs, 54, 452, 459, 460, 523, 526
wires, 48, 452, 461, 523, 526
Speedometer, 160, 535, 540
gear, 140-141, 160, 202
Spicer 18 transfer case
See Model 18, transfer case
Spicer/Dana axles, 210, 212, 226, 234, 238, 258, 261-273, 274, 311, 319, 321
cross-joint axle shaft, 250-259
cross-type U-joint, 250-255
disc brakes for, 384-391
Spicer 44 rear axle, 261-273
swap, 257
Spring anchors, 553
Spring shackle bushings, 343-348
Springs, 340-348
disassembly, 19, 21
Starter motor, 436, 438, 44, 448, 449, 521
Steering system, 366
drag link (See Drag link)
general layout, diagrams of, 371, 372
knuckle, 241-247
stabilizer shock, 553
steering column and steering gear assembly, 372
Ross cam-and-lever steering gear rebuild, 367
steering tube
(See Cam tube/steering tube)
steering wheel, 369-370, 377, 378, 553
Suspension system, 340-348
allowable modifications, Massachusetts law for, 341
lift and upgrades for, 341-342

T

T-14 transmission, 60, 81, 87, 88
T-18 transmission, 60-87, 88-90
T-98A transmission, 60, 68, 81, 86
Tachometer, 446
Tail lamp, 442
Thermostat, 30, 47, 51, 53, 56, 521, 524, 525, 541
Throttle body, 480, 485, 486, 494, 502, 508, 574
Throttle linkage, 486, 514, 527-528
See also Carburetor, throttle linkage
Throwout bearing, 95, 102, 113, 116, 117, 119, 120
Thrust bearing, 93
Tie-rods, 16, 366-367, 372-375
Timing chain, 31-47
Tires, 257, 298-299, 309, 325, 340-341, 343, 248-349, 372, 374, 375, 384, 561
spare tire rack, 560
Tools,
resources, 586-592
trailside toolbox, 592-593
Top, 561-563
Top-dead-center, 523
Tractech, Inc. Truetrac locker, 263-268
Trailside toolbox and spare parts kit, 592-593
Transfer case, 60, 87-90, 97, 126
rebuilding, 128-202
separating, 61
Transmission, 60
See also Mainshaft, transmission
adapters, 81, 87-102
cover plate, 79, 103, 104
crossmember
building, 336-338
diagrams, 62-63, 80
floor plate, 103-111
installation, 94-103
rebuilding of T-18 four speed,
61-80
retrofitting, 81-87, 87-112
synchronizer(s), 61, 64, 72-74, 76, 80, 92
TJ Wrangler five-speed synchromesh transmission (NV3550), 89, 574
Transmission jack, 94-97
Trim, 441, 587-588
Truetrac locker, 263-268
Turn signals, 439-440

U

U-bolts, 17, 342, 343, 347, 348
U-joints, 250-255, 310-314, 314-317
suspension lift, effect of, 314-317
Urethane,
body mounts, 350
bushings, 343, 345-346

V

V-6 engine, 574
See Buick V-6
V-8 engine(s), 24, 27-28, 29, 49, 450, 472, 474, 488, 544, 548, 549, 574
Vacuum lines, 472, 519, 528,
536-539, 543
Valve cover, 30, 35, 527, 536-537
Valve guides, 32
Valve seats, 32
Valve springs, 35
Valves, 32, 33, 40, 48
Valvetrain, 40
Voltage regulator, 444, 462

W

Warn Industries, 586
disc brake upgrade, 384-391
rear-axle conversion kit
(full-floater), 271-273
wheel hubs, 394-398
Water pump, 46, 47, 53, 54-56
Welding and cutting, 325-339
Wheel cylinders
See Brake system
Wheel hubs, 384, 390, 399, 402, 405
bearing service and adjustment, 394-398, 399-407
Wheels, 560, 561
Winches, 599
Windshield, 568
Windshield wipers
electric, 447-448
switch, 447
Wires and wire harnesses,
438-440, 442-446, 448-449
See also Electrical system
OEM wiring diagrams, 464-470