Willys CJ-2A Operation And Care Manual
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Willys CJ-2A Operation And Care Manual

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  • Page 1: And Care

    Your Operation and Care Manual Universal Jeep Model CJ-2A...
  • Page 2 Imitation parts are usually of inferior quality and can do serious damage to other mechanical parts of your vehicle. Genuine parts are sold by all authorized Willys-Overland Dealers. Be sure non other than genuine parts are placed in your vehicle.
  • Page 3 Jeep CJ2A Specifications on The CJ2A Page Engine "Go-Devil" L-Head Number of cylinders........4 Bore...............3 1/8" 79.37 mm. Stroke............4 3/8" 111.12 mm. Piston Displacement........134.2 cu. in. 2199.53 cc. Compression Ratio..........6.48 to 1 Horsepower -- SAE........15.6 Horsepower (actual @ 4,000 RPM)....60 Torque (max. @ 2,000 RPM)......105 Lbs. Ft. Dimensions and Capacities Wheelbase............80"...
  • Page 4 Above 90º F....SAE 30 Not Lower than 32º F...SAE 20 or 30 As Low as +10º F..SAE 20 W As Low as -10º F..SAE 10 W To temperatures below -10º F, use SAE 10 W plus 10% kerosene Valve and Ignition Timing Piston Measurements From Top Centre Inlet opens 9 degrees before top centre...
  • Page 5 During its entire life, never race the engine while making adjustments or when the vehicle is standing idle. It the vehicle is not properly lubricated, our Warranty is null and void. Be sure to have your Willys-Overland Dealer inspect your vehicle at the end of 1000 miles or equivalent usage and every 2500 miles thereafter.
  • Page 6 CJ2A Operation and Care Manual -- Getting Started 1. Windshield Wiper Arm 19. Underdrive Shift Lever 2. Windshield Wiper Blade 20. Front Axle Drive Shift Lever 3. Windshield Centre Lock 21. Transmission Shift Lever 4. Windshield Glass 22. Heat Indicator Gsuge 5.
  • Page 7 FIG. 2 -- SIDE SECTIONAL VIEW OF ENGINE 1. Fan Assembly 14. Exhaust Manifold Assembly 26. Connecting Rod Cap Bolt 39. Crankshaft Oil Seal 2. Water Pump Bearing and Shaft 15. Valve Spring 27. Oil Float Support 40. Starting Crank Nut Assembly Assembly 16.
  • Page 8 Shift the lever into the reverse position, slowly release the clutch pedal and regulate the car speed with the foot accelerator. TO USE THE ENGINE AS A BRAKE. The most effective brake for holding the vehicle back on a steep grade is the engine. To use the engine as a brake, shift into one of the lower speeds before starting to descend.
  • Page 9 STEERING KNUCKLE OIL SEAL. When parking during cold, wet weather, swing the front wheels from right to left to wipe away moisture adhering to the front axle universal joint housings and oil seals, Fig. 5. This will prevent freezing with resulting damage to the oil seal felts.

  • Page 10: Engine Lubrication

    CJ2A Operation and Care Manual -- General Lubrication General Lubrication The use of high grade lubricants and regular application is specially essential when operating the “Jeep” because of the diversified service it performs. The amount of trouble free service received will be in proportion to the care given. Lubricate the vehicle in accordance with the type of service performed.

  • Page 11: Air Cleaner

    of industrial or field use. Drain the filter at each oil change to prevent the old oil contained in the filter from mixing with and contaminating the new oil. Replace the element at each 8000 miles of highway use or 200 hours of industrial or field use. AIR CLEANER.

  • Page 12: Ignition Timing

    Adjust the carburetor low speed idle screw so that the engine will idle smoothly. NOTE: Should the engine fail to perform satisfactorily and the trouble is definitely traced to the carburetor, consult your Willys-Overland Dealer. Carburetor service is specialized and should not be undertaken unless the unit is thoroughly understood.
  • Page 13 Information above is given only to enable the operator to place the vehicle back in service should trouble develop. At the first opportunity, have your Willys-Overland Dealer check the setting with a neon timing lamp which can also be used to check the automatic spark advance...
  • Page 14 CJ2A Operation and Care Manual -- Proper Maintenance (part 2 -- Engine Fails to Start, Oil System) ENGINE FAILS TO START Should the engine suddenly stop or fail to start, check the cause as follows. Also see Emergency Chart. Make sure there is gasoline getting to the carburetor (Note: Should the trouble be traced to the gasoline supply see FUEL SYSTEM) and that the ignition switch is “ON”.
  • Page 15 ENGINE MOUNTINGS The rubber engine mountings, which are attached to the frame side rail brackets and to the support plate, prevent fore-and-aft motion of the engine, yet allow free sidewise and vertical oscillation which neutralizes vibration at the source. Keep the mountings tight.
  • Page 16 FLOATING OIL INTAKE The floating oil intake (No. 28, Fig. 2) is attached to the crankcase with two screws. The construction of the float and screen cause it to remain on top of the oil, preventing the circulation of water and dirt. Once each year remove the float, screen and tube and clean thoroughly with a suitable cleaning fluid.
  • Page 17 VOLTAGE REGULATOR The regulator must be adjusted with great accuracy; hear as well as voltage and amperage must be considered when adjusting it. Should trouble develop in the regulator either consult a Willys-Overland Dealer or install a new one. DISTRIBUTOR ASSEMBLY The distributor delivers the spark to the right cylinder at the right time.
  • Page 18 (see EMERGENCY CARD). Do not disturb the carburetor until it is proven that the trouble is not elsewhere. Should it be determined that the carburetor is at fault consult your Willys-Overland Dealer. The carburetor is provided with an external adjustment to secure smooth engine idle.
  • Page 19 No. 9 is not stuck. CAUTION: Do not attempt repairs which require disassembling of the fuel pump other than cleaning as special care is required. It is recommended that all fuel pump trouble be taken up with your Willys-Overland Dealer. FUEL SUPPLY TANK The capacity of the fuel tank is 10 ½...
  • Page 20 WATER PUMP The water pump assembly Fig. 15 is a centrifugal impeller type, of large capacity to circulate the water in the entire cooling system. The sealed type double-row ball bearing is integral with the shaft and is packed at the time of assembly with a special high melting point grease, so requires no lubrication.
  • Page 21 CJ2A Operation and Care Manual -- Proper Maintenance (part 4 -- Electrical System) ELECTRICAL SYSTEM The wiring diagram (Fig. 16) shows the general arrangement of all of the electrical circuits, together with all the units in correct relation to the position in which they are found. Regular inspection of all electrical connections avoids failures in the electrical system.

  • Page 22: Headlamp Aiming

    Should it be necessary to install a new light switch, refer to the wiring diagram, which indicates the correct wires to install on the several terminals. To remove the switch, loosen the set screw in the side of the switch control knob and remove the knob by unscrewing. The retaining nut may then be removed and the switch removed through the rear of the instrument panel.

  • Page 23: Transmission Assembly

    CJ2A Operation and Care Manual -- Proper Maintenance (part 5 -- Transmission and Axles) CLUTCH The clutch is of the single, dry plate type consisting of a pressure plate assembly, having three pressure springs, three release levers; and a spring cushioned, faced driving plate mounted on a hardened steel, splined hub.
  • Page 24 Poppet balls and springs retain the gears in mesh and an interlock prevents shifting into two gears at one time. Should any trouble be experienced with the transmission assembly, consult your Willys-Overland Dealer. TRANSFER CASE ASSEMBLY The transfer case Fig. 23 is an auxiliary unit located at the rear of the transmission. It is essentially a two speed transmission, which provides a low and direct gear, also a means of connecting the drive to the front axle.

  • Page 25: Rear Axle

    Once each year have your Willys-Overland Dealer remove the front axle universal joint and shaft assemblies to thoroughly wash out the steering knuckle housings and check the shim adjustment of the universal joints. After checking, the universal joint housings must be refilled with good quality lubricant as specified in the LUBRICATION section.
  • Page 26 1. Wheel Hub Cap, 21. Drive Pinion Left or Right Bearing Cup, Front 2. Axle Shaft Nut 22. Drive Pinion 3. Wheel Hub Bearing Cup, Rear 4. Brake Drum 23. Drive Pinion 5. Brake Cylinder Bearing Cone and Assembly, Rear Rollers, Rear 6.
  • Page 27 Back off seven notches on each adjusting screw wheel to secure the correct running clearance between the shoes and the drum. Should either the foot or hand brakes require relining or other extensive work, contact your Willys-Overland Dealer. 1. Brake Hose - Front Axle to 12.
  • Page 28 Do not tighten the steering gear to dampen out steering trouble. Should trouble develop, consult your Willys-Overland Dealer, as he has a definite procedure for the inspection and adjustment of the steering system.
  • Page 29 shims, Fig. 32, No. 2 to adjust the bearing with .001" to .003" end float which will be just perceptible when tested by hand. The shims available for this adjustment are .003" - .005" and .030" thick. Examine the grease retainer to be sure it is serviceable -- replace it if in doubt, and reassemble. MAINTENANCE OF WHEEL BEARINGS When the vehicle is used for road work, lubricate and adjust the front wheel bearings once each year;...
  • Page 30 of the spring. Hold the "U" shackle tightly against the frame bracket and start the upper bushing on the shackle, care being taken when it enters the thread in the frame, that it is not cross-threaded. Screw the bushings on the shackle about halfway, and then start the lower bushing, hold the shackle tightly against the spring eye and thread this bushing about halfway, then alternating from top bushing to lower bushing, turn them in until the head of the bushing is snug against the frame bracket and the bushing in the spring eye is 1/32"...
  • Page 31 CJ2A Operation and Care Manual -- Emergency Chart) No adjustment should be made, or any parts tampered with, until the cause of the trouble is ascertained, otherwise adjustments which are properly made may be destroyed. The trouble should be analyzed first. STARTING MOTOR WILL NOT TURN ENGINE Battery weak.
  • Page 32 Improper valve timing. Clutch slipping. Exhaust pipe or muffler obstructed. LACK OF COMPRESSION Faulty cylinder head gasket. Insufficient tappet clearance. One or more improperly fitted pistons or piston rings. Valves not seating properly. POPPING BACK THROUGH THE CARBURETOR (This usually indicates a too lean mixture.) Dirt in carburetor.
  • Page 33 CJ2A Operation and Care Manual -- Extra Equipment) Much of the utility of the Jeep is due to the extra equipment which has been designed to adapt it for farming and diversified occupations and industries. The maintenance and use of this equipment is outlined in the following paragraphs. GOVERNOR (KING SEELY) The governor is a centrifugal type unit which gives precision control of engine speeds.
  • Page 34 Change the oil in the governor at each engine oil change, using the same grade oil used in the engine. Fill it to the level plug opening slowly – do not overfill. Should any trouble occur which requires disassembly, consult your Willys-Overland Dealer.
  • Page 35 The other gear may be removed in the same manner after removing cover plate. Interchange the gears and reassemble in reverse order with the long side of the gear hub toward the cover opening. Use care that the shims are replaced in the same position relative to the bearings from which they were removed.
  • Page 36 Also select the correct upper side rail (a rod approximately 30” long with one end curved) which will assemble with the curved end next to the windshield with the curve extending up and out and with the welded eye extending in. After selecting the correct parts install the clamp bracket, with the stud extending in and place the eye in the curved end of the side rail over the stud on the inside of the clamp bracket.
  • Page 37 CJ2A Operation and Care Manual -- Plowing Method, PTO and Vehicle Speeds) To avoid loss of time and minimize turning at the headlands while plowing a field, the following procedure is recommended: Lay out the field lengthwise in convenient lands or sections as shown by the back furrows in Fig.
  • Page 38 High 10.81 1074 19.51 1666 30.25 10.81 1547 19.51 2400 30.25 4.89 1182 8.83 1833 13.70 4.89 1702 8.83 2640 13.70 2200 High 11.89 1182 21.46 1833 33.27 11.89 1702 21.46 2640 33.27 5.34 1289 9.63 2000 14.94 1028 5.34 1856 9.63 2880...
  • Page 39 CJ2A Operation and Care Manual -- Directions for Ordering Parts) When new parts are necessary, it is recommended that these be ordered from the nearest Willys-Overland Dealer. Do not order parts in a letter in which some other subject is treated.
  • Page 40 CJ2A Operation and Care Manual -- Lubrication Chart FIG. 17 -- CHASSIS, SHOWING PARTS REQUIRING LUBRICATION Chassis Bearings, Nos. 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 Ignition Distributor, No. 19 Clean and lubricate each 1000 of road service. Make certain each Lubricate each 1000 miles or equivalent in field service.

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