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Kaiser-Jeep Manuals
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Jeep CJ-3B
Service manual
Kaiser-Jeep Jeep CJ-3B Service Manual
Jeep universal cj-3b/cj-5a/cj-5/cj-6/cj-6a; dj-5/dj-6
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Engine Code Number
General Data
Identification Number Location
Vehicle Serial Number
Paint-And-Trim Option Plate
Specifications
Table of Contents
Lubrication and Periodic Services
Lubrication Chart
Applying Fresh Lubricant
Engine Lubrication System
Oil Pressure Gauge or Indicator
Special Lubricants
Chassis Lubrication
Engine Oil
S E R V I C E Maintenance Schedule
Air Cleaner
Engine Oil Filter Service
Exhaust Manifold Heat Control Valve
Fan Belt
Generator Lubrication
Positive Crankcase Ventilation System Lubrication
Dry-Type Air Cleaner
Oil Bath Air Cleaner View
Cooling System Lubrication
Steering Gear Lubrication
Transmission and Transfer Case Lubricant Check and Change
Brake Master Cylinder Lubrication
Conventional Differentials
Power-Lok or Trac-Lok Differential Lubrication
Transfer Case Linkage Lubrication
Centrifugal Governor Lubrication
Front Axle Wheel Bearings Lubrication
Headlights
Lubrication of Optional Equipment
Pintle Hook
Parts Requiring no Lubrication
Lubrication Requirements for Off-Highway Operation
Air Cleaner Care
Front and Rear Axle Differentials Care
Propeller Shafts and Universal Joints Lubrication
Rear Axle Wheel Bearings Lubrication
Part S R E Q U I R I N GNO L U B R I C a T I O N
Alternator Bearings
Shock Absorbers
Starter Motor Bearings
Engine Oil
Tune-Up
Clean and Check Battery
Clean and Adjust Spark Plugs
Torque Cylinder Head(S) and Manifold
Service Crankcase Ventilating System
Crankcase Ventilation Valve System Diagram
Positive Crankcase Ventilation System Diagram
Service Manifold Heat Control Valve
Check Valve Tappet Clearance
Check Engine Cylinder Compression
Compression Pressure Limit Chart
Contact Points Material Transfer
Distributor Service
Replacement and Adjustment of Prestolite Distributor Point Set
Braker Lever Spring Tension
Replacement and Adjustment of Delco Distributor Point Set
Check Ignition Timing
Engine Timing Marks
Distributor Rotation and Firing Order
Primary Circuit Tests
Distributor Resistance Test
Distributor Point Dwell
Test Ignition Cables
Coil
Check Fuel Lines and Screens
Check Manifold Vacuum
Carburetor Adjustments
Carburetor View
Road Test Vehicle
Check Fan Belt
Service Diagnosis
Poor Fuel Economy
Overheating
Excessive Oil Consumption
Tune-Up Specifications
Hurricane F4 Engine
Engine Description
Engine Mountings
G E N E R a L
Hurricane F4 Engine Diagrams
Camshaft
Engine Ground Strap
Engine Removal
Engine Disassembly
Remove Distributor
Remove Oil Pump
Remove Rocker Arm Assemblies
Remove Cylinder Head
Exhaust Manifold
Engine Exploded View
Remove Piston and Connecting Rod Assemblies
Remove Flywheel
Remove Crankshaft
Oil P a N
Ream Cylinder Bore Ridges. D-L8
Engine Inspection and Repair
Remove Exhaust Valves and Springs
Remove Camshaft
Remove Valve Tappets
E N G I N E I N S P E C T I O N and R E P a I R
Cleaning
Cylinder Bores
Pistons, Rings and Connecting Rods
Piston Fitting
Piston Pin Fitting
Checking Connecting Rod Alignment
Connecting Rod and Piston
Checking Piston and Connecting Rod Alignment
Checking Piston Ring Side Clearance
Piston Ring Gap
Piston Ring Application Chart
Crankshaft Inspection and Repair
Checking Crankshaft Alignment
Checking Main Bearing Journals
Checking Connecting Rod Crankpins
Fitting Crankshaft Main Bearings Using Shim Stock
Crankshaft Main Bearing Inspection
Connecting Rod Bearings
Connecting Rod Bearing Inspection
Installing Connecting Rod Bearings
Camshaft and Bearings
Camshaft Front Bearing Replacement
Camshaft End Play
Timing Gears and Cover
Valves, Springs, and Guides Inspection
Testing Valve Spring
Refacing Valves
Valve Seat Inspection and Refacing
Exhaust Valve Seat Insert Replacement
Valve Guide Replacement
Valve Guide Driver
Valve Guide Positions
Tappets and Cover
Crankshaft Rear Bearing Seal
Floating Oil Intake
Oil Pump
Oil Filter, Oil Pan, Oil Pump and Lines Diagram
Oil Pan
Floating Oil Intake and Pan
Oil Pump Diagram
Flywheel Inspection
Ring Gear Replacement
Flywheel Pilot Bushing
Flywheel Housing
Core Hole Expansion Plug
Cylinder Head
Rocker Arms
Rocker Arm Shaft Disassembly
Crankcase Ventilation Valve View
Engine Reassembly
Install Oil Gallery Plugs
Install Tappets
Install Camshaft and Thrust Plate
Inspection
E N G I N E R E a S S E M B L y
Install Crankshaft and Bearings
Check Crankshaft End-Play
Valves, Camshaft and Timing Gears Diagram
Install Crankshaft Timing Gear
Install Crankshaft Rear Bearing Seal
Install Front End Plate
Install Flywheel
Install Flywheel Housing
Install Clutch
Install Valves and Springs
Install Camshaft Timing Gear
Install Timing Gear Oil Jet
Install Oil Pump
Install Pistons and Connecting Rods
Install Oil Pan
Install Cylinder Head
Install Rocker Arm Assembly
Install Distributor and Spark Plugs
Engine Installation
Install Manifold
Install Oil Filter Tube
Install Water Pump
Valve Adjustment
Check Valve Timing
Positive Crankcase Ventilation
Oil Filter
Engine Service Diagnosis
Lack of Power
Low Compression
Burned Valves and Seats
Hurricane F4 Engine Specifications
Crankshaft Timing Gear
Dauntless V-6 Engine
Cylinder Head
Distributor D L
Flywheel
M a N I F O L D
Oil Pan
Oil Pump
E N G I N E I N S T a L L a T I O N
Oil Filter
Dauntless V-6 Engine Description
Dauntless V-6 Engine Diagrams
Engine Removal (Dauntless V-6)
Engine Disassembly (Dauntless V-6)
Engine Mounts (Dauntless V-6)
Mounting Engine on Engine Stand (Dauntless V-6)
Remove Distributor (Dauntless V-6)
Remove Fuel Pump (Dauntless V-6)
Remove Alternator and Fan Belt (Dauntless V-6)
Cooling F a N and Water Pump
Carburetor Assembly
Remove Crankshaft Vibration Damper (Dauntless V-6)
Remove Timing Chain Cover (Dauntless V-6)
Remove Timing Chain and Sprocket (Dauntless V-6)
Engine Lubrication and Cooling Parts (Dauntless V-6)
Remove Rocker Arm Cover (Dauntless V-6)
Engine Crankcase Parts (Dauntless V-6)
Remove Cylinder Head Assembly (Dauntless V-6)
Remove Push Rod and Valve Lifter (Dauntless V-6)
Remove Flywheel Housing and Clutch (Dauntless V-6)
Remove Piston and Connecting Rod Assembly (Dauntless V-6)
Engine Cleaning, Inspection and Repair
Remove Main Bearing and Crankshaft
Cylinder Block Cleaning
Cylinder Block Inspection
Cylinder Block Repair (Dauntless V-6)
Crankshaft Cleaning, Inspectiona and Repair (Dauntless V-6)
Crankshaft Main Bearings (Dauntless V-6)
Crankshaft Main Bearing Cleaning and Inspection (Dauntless V-6)
Main Bearing Fitting, Plastigage (Dauntless V-6)
Main Bearing Fitting, Feeler or Shim Stock (Dauntless V-6)
Piston and Connecting Rod Disassembly (Dauntless V-6)
Piston and Connecting Rod Cleaning and Inspection (Dauntless V-6)
Piston Pin Removal (Dauntless V-6)
Piston Fitting (Dauntless V-6)
Piston Ring Fitting (Dauntless V-6)
Piston and Connecting Rod Assembly (Dauntless V-6)
Connecting Rod Bearing Inspection and Fitting (Dauntless V-6)
Left/Right Bank Piston and Rod Assembly View
Piston Rings View
Flywheel Cleaning and Inspection (Dauntless V-6)
Ring Gear Replacement (Dauntless V-6)
Flywheel Housing Cleaning and Inspection (Dauntless V-6)
Valve Lifter and Push Rod Cleaning and Inspection (Dauntless V-6)
Removing Plunger from Valve Lifter Body
Hydraulic Valve Lifter Wear Patterns
Hydraulic Valve Lifter Leak-Down Test (Dauntless V-6)
Rocker Arm Disassembly (Dauntless V-6)
Rocker Arm Cleaning and Inspection (Dauntless V-6)
Rocker Arm Assembly (Dauntless V-6)
Valve Removal (Dauntless V-6)
Cylinder Head and Valve Cleaning and Inspection (Dauntless V-6)
And Inspection D1-65
Cylinder Head and Valve Repair (Dauntless V-6)
Valve Installation (Dauntless V-6)
Engine Reassembly (Dauntless V-6)
Rocker Arm Cover Cleaning and Inspection (Dauntless V-6)
Timing Chain Cover Cleaning and Inspection (Dauntless V-6)
Oil Pump Cleaning and Inspection (Dauntless V-6)
Timing Chain and Sprocket Inspection
E N G I N E R E a S S E M B L y
Cylinder Block and Crankshaft Rear Oil Seals (Dauntless V-6)
Main Bearing and Crankshaft Installation (Dauntless V-6)
Crankshaft End Play Check (Dauntless V-6)
Piston and Connecting Rod Installation (Dauntless V-6)
Install Oil Pump Intake Pipe and Screen Assembly (Dauntless V-6)
Install Oil Pump (Dauntless V-6)
Install Flywheel (Dauntless V-6)
Oil Pan and Pump Assembly View (Dauntless V-6)
Install Clutch and Flywheel Housing (Dauntless V-6)
Install Camshaft (Dauntless V-6)
Install Valve Lifter and Push Rod (Dauntless V-6)
Install Cylinder Head Assembly (Dauntless V-6)
Install Timing Chain and Sprocket (Dauntless V-6)
Install Crankshaft Front Oil Seal (Dauntless V-6)
Timing Chain, Timing Gears and Cover Diagram (Dauntless V-6)
Install Timing Chain Cover (Dauntless V-6)
Fuel Pump Eccentric and Distributor Drive Gear View
Install Crankshaft Vibration Damper (Dauntless V-6)
Install Crankshaft Pulley (Dauntless V-6)
Install Alternator and Fan Belt (Dauntless V-6)
Install Fuel Pump (Dauntless V-6)
Install Spark Plugs (Dauntless V-6)
Install Intake Manifold and Carburetor Assembly (Dauntless V-6)
Engine Installation (Dauntless V-6)
Final In-Vehicle Adjustment (Dauntless V-6)
Service Diagnosis - Dauntless V-6 Engine
Dauntless V-6 Engine Specifications
Fuel System
Fuel Evaportive Emission Control System
Fuel Pump
Canister
Demand Valve
Fuel Evaporative Emission Control System Diagram
Fuel Tank
Vapor Separator or Expansion Tank
Sealed Gas Cap
Carburetor
Fuel Emission Vent System Inspection Test
Fuel Emission Vent System Servicing
Float System
Float Adjustment
Low-Speed System
Idle Mixture Adjustment
High-Speed System
Metering Rod Adjustment
Choke System
Fast Idle Adjustment
Accelerating Pump System
Accelerating Pump Maintenance
Carburetor Disassembly
Carburetor Reassembly
Correcting Acceleration Flat Spot
Carburetor - Dauntless V-6 Engine
Steep-Grade Carburetor Kit
Float System (Dauntless V-6)
Idle System (Dauntless V-6)
Main Metering System (Dauntless V-6)
Power System (Dauntless V-6)
Accelerator Pump System (Dauntless V-6)
Choke System (Dauntless V-6)
Carburetor Removal (Dauntless V-6)
Air Horn Body Removal and Disassembly (Dauntless V-6)
Throttle Body Removal and Disassembly (Dauntless V-6)
Throttle Body Assembly (Dauntless V-6)
Fuel Bowl Body Assembly (Dauntless V-6)
Air Horn Body Assembly (Dauntless V-6)
External Carburetor Adjustment (Dauntless V-6)
Accelerator Pump Adjustment (Dauntless V-6)
Curb Idle Speed and Mixture Adjustments (Dauntless V-6)
Float Drop Adjustment
Fuel Pump (Double-Action) - Hurricane F4 Engine
Fast Idle Adjustment (Dauntless V-6)
Dash Pot Adjustment
Fuel Pump Disassembly
Fuel Pump (Single-Action) - Hurricane F4 Engine
Fuel Pump Assembly
Vacuum Pump
Vacuum Booster Check
Fuel Pump Removal
Fuel Pump Disassembly (Hurricane F4)
Fuel Pump Cleaning and Inspection
Fuel Pump Reassembly
Fuel Pump Installation (Hurricane F4)
Fuel Pump - Dauntless V-6 Engine
Air Cleaner
Accelerator Linkage
Fuel Tank and Fuel Lines
Fuel Tank Removal
Fuel Tank Installation
Accelerator Linkage - V-6 Engine
Fuel Tank Cap
Fuel Gauge Float Unit
Fuel Lines
Fuel System Service Diagnosis
Engine Hesitates on Acceleration
Engine Stalls - Won't Idle
Fuel System Service Specifications
Exhaust System
Exhaust System Maintenance Requirements
Exhaust System Servicing
Exhaust Manifold Installation
Heat Control Valve Replacement
Exhaust System Specifications
Exhaust Pipe Replacement
Muffler Removal and Replacement
Tail Pipe Removal and Replacement
Exhaust Emission Control System
Air Pump
Pump Air Filter
Air Injection Tubes
Exhaust Emission Control System Maintenance
Carburetor Idle Setting
Removal of Major Units of the Exhaust Emission Control System
Anti-Backfire Diverter Valve
Check Valve
Air Distribution Manifold and Injection Tubes
Exhaust Emission Control System Diagnosis Guide
Exhaust Emission Control System Maintenance Chart
Exhaust Emission Control System Specifications
Data Tag
Exhaust Emission Control System (Dauntless V-6 Engine)
Heaterd Air System (Dauntless V-6)
Exhaust Emission Control System (Dauntless V-6) Maintenance
Testing Thermo Air Cleaner Operation
Carburetor Air Cleaner - Dry Type
Positive Crankcase Ventilator Valve
Replacement of Vacuum Motor
Air Delivery Manifold
Anti-Backfire Valve
Replacement of Air Cleaner Sensor
Removing the Major Units from the Exhaust Emission Control System
Distributor
Intake Manifold
Air Pump Removal
Anti-Backfire Valve Removal
Air Distribution Manifold and Injection Tubes Removal
Cooling System
Coolant Flow Diagram
Cooling System Components View
Radiator
Filling Cooling System
Draining Cooling System
Radiator Pressure Cap
Radiator Removal and Replacement
Radiator Hoses and Heater Hoses
Pressure Testing Cooling System
Cylinder Block
Thermostat
Temperature Sending Unit
Water Pump Inspection
Water Pump Disassembly
Water Pump Reassembly
Antifreeze Solutions
Inhibited Coolant Solutions
Fan Belt
Engine Overheating
Cooling System Service Diagnosis
Cooling System Specifications
Antifreeze Chart
Loss of Cooling Liquid
Electrical System
Battery
H - L
Primary Circuit
Ignition System
Secondary Circuit
Alternator Charging System
Starting System
Wiring Diagrams
Prestolite Distributor
Distributor Cap
Rotor
Condenser
Distributor Points
Governor Mechanism
Distributor Removal
Prestolite Distributor Disassembly
Delco Distributor
Distributor Inspection
Installation and Ignition Timing
Ignition Coil
Centrifugal Advance
Distributor Removal (Delco)
Distributor Disassembly (Delco)
Distributor Parts Cleaning and Inspection (Delco)
D I S T R I B U T O R - D a U N T L E S S V-6 E N G I N E
Distributor Reassembly (Delco)
Distributor Installation and Timing (Delco)
Coil - V6 Engine
Ballast Resistor
Spark Plugs
Generator - F4 Engine
Generator Maintenance
Generator Disassembly
Armature
Field Coils
Brush Holders
Assembling Generator
Generator Exploded View
Current-Voltage Regulators
Circuit Breaker
Voltage Regulator
Current-Limiting Regulator
Regulator Inspection
Regulators Testing
Low Charging Rate with a Fully Charged Battery
High Charging Rate with a Fully Charged Battery
Cleaning of Contacts
Low Battery and a Low or no Charging Rate
Alternator Precautions
Alternator Charging System Service
Alternator in Vehicle Tests
A L T E R N a T O R C H a R G I N G S y S T E M
Alternator Output Test
Isolation Diode Test
Isolation Diode Check
Alternator Output Test
Regulator Test
Removal and Installation of Voltage Regulator
Alternator Field Circuit Test
Brush Removal and Inspection
Brush Insulation and Continuity Test
Alternator Bench Tests
Alternator Removal
Rotor Tests - Bench
Alternator Disassembly
A L T E R N a T O R B E N C H T E S T S
A L T E R N a T O R R E M O V a L
Alternator Inspection
Alternator Exploded View
H - 8 1 . G E N E R a L I N S P E C T I O N
Out-Of-Circuit Rotor Test
Out-Of-Circuit Stator Leakage Test
Stator Coil Leakage and Continuity Test
Out-Of-Circuit Rectifier Diode Test
Assembling Alternator
Alternator Installation
Starting System Service
Prestolite Starting Motor
Ignition Switch Removal
Ignition Switch Installation
Starting Motor Maintenance
Commutator
Starting Motor Removal and Installation
Brushes
Prestolite Starting Motor Exploded View
Brush Holder Inspection
Starting Motor Reassembly
Starting Motor Bench Test
Bendix Folo-Thru Drive (Prestolite)
Lubrication of Folo-Thru Drive
Starter Solenoid Switch (Prestolite)
Delco Starting Motor Diagram
Starting Motor - Delco Dauntless V-6 Engine Disassembly and Inspection
Starting Motor - Delco Dauntless V-6 Engine Reassembly
Installing Pinion Stop Retainer and Thrust Collar on Armature Shaft
Measuring Pinion Clearance
Electrical Instruments
Starting Motor No-Load Test
Locked Armature Test
Fuel Gauge
Lighting System
Testing Indicators and Gauges
Main Light Switch
Headlight Dimmer Switch
Stop Light Switch
Head Lamp Replacement
Head Lamp Aiming Preparation
Aiming Head Lamps
Parking and Turn Signal Light
Tail, Stop and Turn Signal Light
Backup Lights
License Plate Light
Horn
Directional Signals
Hazard Warning Lights
Marker Lights and Reflector Assembly
Two-Speed Wiper Motor
Wiper Troubleshooting in Vehicle
Wiper Troubleshooting on Bench
Disassembly/Reassembly of Two-Speed Wiper Motor
Cleaning of Two-Speed Wiper Motor
No Load Testing
Major Electrical Component Replacement
Two-Spee Wiper Motor Exploded View
Electrical System Service Diagnosis
Battery Discharged
Alternator Problems
Generator Problems
Starting Motor - Slow Starter Speed
Distributor - Hard Starting
Lights Problems
Generator Fails to Charge
Horn Fails to Sound
Horn Sounds Unsatisfactory Tone
Electrical Specifications
Clutch
1-1. General
1-2. Clutch Maintenance
1-3. Clutch Pedal Linkage and Adjustment
Clutch Removal (Hurricane F4)
Cluch Pressure Plate and Disc Inspection (Hurricane F4)
Clutch Pressure Plate Adjustment - Auburn (Hurricane F4)
1-4. Clutch - Hurricane F4 Engine
1-6. Clutch Pressure Plate and Disc Inspection
Clutch Fitxure
1-5. Clutch Removal
Pilot Bushing Inspection and Replacement
Clutch Installation
Clutch - Dauntless V6 Engine
Clutch Removal (Dauntless V6)
Clutch Inspection (Dauntless V6)
1-12. Clutch Inspection
Diaphragm Spring Type
Servicing Clutch Pressure Plate and Disc - Borg & Beck V6
Clutch Pressure Plate Adjustment (Dauntless V6)
Inspection of Clutch Parts
Clutch Disassembly (Dauntless V6)
Inspect Clutch Pressure Springs
Inspect Clutch Adjusting Levers
Clutch Pressure Plate Assembly and Adjustment
Inspect Pressure Plate and Disc
Assemble Clutch Levers
Assemble Clutch Spring and Cover
Clutch Lever Adjustment
Clutch Throwout Release Bearing
Checking Levers for Free Movement (Clutch)
Clutch Height Adjustment
Fabricating Clutch Fixture
Mounting Fixture Hole Dimensions
Gauge Fabricating Dimensions
Clutch Throwout Bearing Collar - Lubricating Points
Clutch Throwout Bearing Installation
1-27. Clutch Installation
Control Lever and Tube Diagram
Clutch Service Diagnosis
Clutch Specifications
Clutch Dragging
Clutch Rattling
Three-Speed Transmission
Transmission Shifting Control
Transmission Remote Control Adjustment
Removal of Remote Control
Transmission Removal
Reassembly of Remote Control
Three-Speed Transmission Diagram
Separating Transmission and Transfer Case
Transmission Disassembly
Transmission Interlocking Sleeve Inspection
Shift Lock Plate View
Countershaft Bearing Spacers View
Interlock Sleeve Clearance View
Transmission Inspection
Transmission Reassembly
Transmission - T96
Transmission Cleaning and Inspection
Cane Shift Control Housing Assembly View
T14A Transmission
Transfer Case Drive Gear Assembly View
Removing Main Drive Gear Bearing
Removing Mainshaft Bearing
Removing-Installing Mainshaft Gear Assembly
Removing-Installing Lockplate
Removing-Installing Countershaft
Removing-Installing Reverse Idler Gear
Disassembly Synchronizer Assemblies
Second-Third Synchronizer Assembly
Transmission Reassembly - T14A
Countershaft Gear Bearing Arbor View
Countershaft Bearings and Spacers Installed View
Lockplate Installation
Main Drive Gear Roller Bearings Installed View
Installing Main Drive Gear Assembly
Installing Main Drive Gear Bearing
Installing Main Shaft Bearing
Installing Main Drive Gear Bearing Retainer
Mainshaft Gear Train - Neutral
Installing Cane Shift Cover Assembly
Transmission Service Diagnosis
Transmission Specifications
Four-Speed Transmission
Four-Speed Transmission Removal
Four-Speed Transmission Main Drive Gear View
Four-Speed Transmission Main Shaft View
Four-Speed Transmission Disassembly
Four-Speed Transmission Control Parts View
Four-Speed Transmission Control Housing Disassembly
4-Speed Transmission Reassembly
Assembling Second Speed Synchronizer
Four-Speed Transmission Control Housing Reassembly
Snap Ring and Thrust Washer Installation
Second-Speed Gear Assembly
Installing 4-Speed Transmission
Adapter Plate Oil Seal
Four-Speed Transmission Service Diagnosis
Four-Speed Transmission Specifications
Transfer Case Description
Transfer Case Removal
Transfer Case View - Two Shift Lever
Transfer Case View - One Shift Lever
Transfer Case Disassembly
Universal Joint Flange Puller View
Transfer Case Shift Linkage View
Bearing Cone Removing Wedge View
Front Bearing Cap Disassembly
Rear Cap Disassembly
Bearing Cup Removing Ring View
Shift Rod Oil Sealer Installer View
Transfer Case Reassembly
Thrust Washer Pilot View
Output Shaft Snap Ring Installer View
Output Shaft Oil Seal Driver View
Transfer Case Service Diagnosis
Transfer Case Specifications
Transfer Case Linkage Adjustment
Propeller Shafts and Universal Joints
Needle Bearing and Trunnion Universal Joint
Snap Ring Type Disassembly
Universal Joints View
Propeller Shafts and Universal Joints Specifications
Snap Ring Type Assembly
U-Bolt Type Disassembly
U-Bolt Type Assembly
4-Wheel Drive Front Axle
Front Axle Removal
Hub Cap Puller View
Front Axle Shaft Removal
Axle Shaft Universal Joint Service
Removing and Overhauling Differential
Axle Shaft Drive Flange Puller View
Cardan Cross Universal Joint View
Steering Knuckle and Wheel Bearings View
Axle Shaft Installation
Steering Knuckle Service
Reassemble and Bearing Preload
Replacing Steering Knuckle Oil Seal
Front Axle Installation
2-Wheel-Drive Front Axle
Removal of Solid Front Axle
Front Steering Knuckle View
Front Axle View
Steering Knuckle Pin Replacement
Front Axle Service Diagnosis
Low Speed Shimmy of Wheel Fight
High Speed Shimmy of Wheel Flight
Wandering
Front Axle Specifications
Rear Axle Description
Rear Axle Shaft Removal and Installation
Axle Model Identification
Ratio, Powr-Lok and Trac-Lok Differential Identification
Semifloating Rear Axle - Tapered Shaft View
Wheel Hub Puller View
Rear Axle Shaft Removal (Semi-Float-Flanged Shaft)
Semi-Float Rear Axle Assembly - Flanged Shaft View
Unit Bearing
Removing Flanged Axle Shaft
Lubricating Unit Bearing
Unit Bearing Removal
Rear Axle Shaft and Bearing Installation (Semi-Float-Flanged Shaft)
Notching Bearing Retaining Ring
Removing Axle Shaft Bearing
Rear Axle Assembly
Rear Axle Removal
Axle Shaft Bearing Installed View
Removing Pinion Shaft Oil Seal
Differential Case Disassembly
Differential Carrier Spreader Tool View
Removing Lock Pin
End Yoke Holding Wrench View
Pinion and Differential Case Bearing Removal
Pinion Bearing Cup Removal, Cleaning, Inspection
End Yoke Puller View
Removing Cone and Roller with Puller
Pinion Installation and Adjustment
Pinion Adjusting Fixture
Setting Pinion Gauge
Checking Pinion Adjustment
Differential Case Reassembly
Differential Shim Pack Locations
Adjustment of Differential Side Gears
Adjustment of Differential Bearing Preload and Ring Gear Backlash
Checking Side Gear Clearance
Differential Bearing Driver
Installing Inner Oil Seals
Checking Ring Gear Backlash
Gear Tooth Contact
Powr-Lok Differential
Trouble Symptoms and Possible Causes
Pinion Shaft Oil Seal Installer
Powr-Lok Differential Disassembly and Reassembly
Plate Assembly Order
Trac-Lok Differential Description
Trac-Lok Lubrication
Trac-Lok Troubleshooting
Trac-Lok Differential Disassembly and Reassembly
Trac-Lok Inspection
Plate and Disc Identification
Lubricating Trac-Lok Components
Installing Plate Retainer Clips
Install Differential Case on Axle Shaft
Positioning Gear Rotating Tool
Threading Forcing Screw into Rotating Tool
Rotating Pinion Mate Gears into Position
Installing Pinion Mate Washers
Installing Rear Axle
Complete Trac-Lok Assembly Replacement
Installing Cross Pin
Torquing Ring Gear Screws
Rear Axle Service Diagnosis
Backlash
Rear Wheel Noise
Axle Noisy on Pull and Coast
Rear Axle Specifications
Steering System
Steering Linkage View
Steering Gear Function
Steering Linkage
Steering Column and Gear Alignment
Steering Gear Adjustment
Front Wheel Alignment Adjustment
Front Wheel Toe-In
Toe-In Adjustment
Front Wheel Camber
Axle Caster
Front Wheel Turning Angle
Steering Knuckle Arm
Front Wheel Shimmy
Steering Linkage Service
Steering Connecting Rod (Drag Link)
Tie Rod
Tie Rod Removal
Steering Bellcrank Service
Steering Column and Wheel Service
Steering Gear Service
Bellcrank Support Bracket Rivet Replacement
Removal of Steering Gear
Disassembly of Steering Gear
Reassembly of Steering Gear
Installation of Steering Gear
Steering Wheel Insatallation
Steering System Service Diagnosis
Steering Specifications
Brakes
Master Cylinder - Double Safety Brake System
Parking Brakes
Parking Brake Linkage
Transmission Brake
Brake Maintenance
Brake Service
Bleeding Brakes
Brake Hoses
Brake Pedal Adjustment
Hand Brake
Parking Brake Adjustment
Transmission Brake Adjustment
Relining Transmission Brake
Self-Adjusting Wheel Brake Units
Relining Wheel Brakes
Brake Shoe Removal
Brake Shoe Inspection
Brake Shoe Installation
Wheel Hub Oil Seal Driver
Standard Front Wheel Brake Assembly with Link Type Adjuster
Installing the Rear Brake Shoes
Brake Shoe Initial Adjustment
Master Cylinder Reconditioning - Dual System
Master Cylinder Reassembly
Double Safety Master Cylinder View
Removing Tube Seats
Brakes Troubleshooting
Wheel Cylinder Reconditioning
Squeaky Brakes
Rattles in Brakes
Brakes Service Diagnosis
Brakes Drag
Brake Grabs - Vehicle Pulls to One Side
Excessive Pedal Pressure
Wheels
Wheel Balancing
Front Wheel Attaching Parts - 4-Wheel Drive
Wheel Bearing Service
Rear Wheel Attaching Parts - 4-Wheel Drive Tapered Axle
Rear Wheel Attaching Parts - 2-Wheel-Drive-Tapered Axle
Checking Front Wheel Bearings
Front Wheel Bearing Adjustment
Rear Wheel Bearing Adjustment - Flanged Axle Shaft
Checking Rear Wheel Bearings - Tapered Axle
Rear Wheel Mounting - Tapered Axle
Brake Drum Service
Tire Service
Rear Wheel Bearing Adjustment - Tapered Axle
Tire Care
Tire Removal and Installation
Tire Wear Pattern
Underinflation/Overinflation
Wheel and Tire Specifications
Tire Rotation
Frame
Checking Frame Alignment
Frame Assembly Diagram
Frame Assembly Measurements
Frame Specifications
Frame Dimensions
Straightening Frame
Draw Bar
Springs and Shock Absorbers
Spring Shackles
Pivot Bolts
Remove Spring
Install Spring
U-Shackles
Shock Absorbers
Spring Pivot Bolt View
Front Spring Shackle View
Spring Specifications
Shock Absorber Specifications
Body
Windshield
Windshield Glass
Canvas Tops
Vehicle Controls View
Tail Gate Assembly View
Care of Fabric Tops
Brake and Clutch Pedal Pads
Front Seat Adjustment
Passenger Seat Safety Catch
Miscellaneous
Extra Equipment
Governor Adjustment
Novi Governor Operation
Pintle Hook Installation
Front Bumper Weight
Fresh Air Heater and Defroster
Special Tools
Engine Torque Specifications
Special Chassis Torque Specifications
Chassis and Body Bolt Torque Chart
Draw Bar Pull
Power Take-Off Shaft and Vehicle Ground Speeds
Spline Shaft Horsepower
Pulley Speeds
List of Abbreviations
Alphabetical Index
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Table of Contents
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1953-71
SERVICE
MANUAL
J
e
e
P UNIVERSAL
4-WHEEL DRIVE
CJ-3B
CJ-5A
CJ-5
CJ-6
CJ-6A
2-WHEEL DRIVE
DJ-5
DJ-6
Copyright® 1977
FI Jeep Corporation
Corporate Publications
Printed in USA
Reprinted 6-77
SM-1046
S E C T I O N
I N D E X
NAME
Section
General Data
A
Lubrication
B
T u n e - U p
C
Hurricane F4 Engine
D
Dauntless V-6 Engine
Dl
F u e l System
E
Exhaust System
F
Exhaust Emission Control
System F4 Engine
F l
Exhaust Emission Control
System V6-225 Engine
F 2
Cooling System
G
Electrical
H
C l u t c h
I
3-Speed Transmission
J
4-Speed Transmission
J l
Transfer Case
K
Propeller Shafts
L
Front Axle
M
Rear Axle
N
Steering
0
Brakes
P
Wheels
0
F r a m e
R
Springs
Shock Absorbers
S
Body
T
Miscellaneous
U
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
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Table of Contents
Troubleshooting
Hazard Warning Lights
217
Wiper Troubleshooting on Bench
218
Trac-lok differential description
303
Brakes troubleshooting
333
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This manual is also suitable for:
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