Kaiser-Jeep Jeep DJ-5 Manuals

Manuals and User Guides for Kaiser-Jeep Jeep DJ-5. We have 1 Kaiser-Jeep Jeep DJ-5 manual available for free PDF download: Service Manual

Kaiser-Jeep Jeep DJ-5 Service Manual

Kaiser-Jeep Jeep DJ-5 Service Manual (377 pages)

Jeep Universal CJ-3B/CJ-5A/CJ-5/CJ-6/CJ-6A; DJ-5/DJ-6

Brand: Kaiser-Jeep | Category: Automobile | Size: 20 MB

Table of Contents

Contents
3
Engine Code Number
4
General Data
4
Identification Number Location
4
Vehicle Serial Number
4
Paint-And-Trim Option Plate
5
Specifications
6
Table of Contents
7
Lubrication and Periodic Services
7
Lubrication Chart
8
Applying Fresh Lubricant
10
Engine Lubrication System
10
Oil Pressure Gauge or Indicator
10
Special Lubricants
10
- Chassis Lubrication
  11
- Engine Oil
  12
S E R V I C E Maintenance Schedule
12
Air Cleaner
13
Engine Oil Filter Service
13
Exhaust Manifold Heat Control Valve
13
Fan Belt
13
Headlights
17
Lubrication of Optional Equipment
17
Part S R E Q U I R I N GNO L U B R I C a T I O N
18
- Alternator Bearings
  18
- Shock Absorbers
  18
- Starter Motor Bearings
  18
- Engine Oil
  18
  - Tune-Up
    19
  - Clean and Check Battery
    20
  - Clean and Adjust Spark Plugs
    20
  - Torque Cylinder Head(S) and Manifold
    21
  - Service Crankcase Ventilating System
    21
  - Crankcase Ventilation Valve System Diagram
    22
  - Positive Crankcase Ventilation System Diagram
    23
  - Service Manifold Heat Control Valve
    24
  - Check Valve Tappet Clearance
    24
  - Check Engine Cylinder Compression
    24
  - Compression Pressure Limit Chart
    25
  - Contact Points Material Transfer
    25
  - Distributor Service
    26
  - Replacement and Adjustment of Prestolite Distributor Point Set
    27
  - Braker Lever Spring Tension
    27
  - Replacement and Adjustment of Delco Distributor Point Set
    28
  - Check Ignition Timing
    28
  - Engine Timing Marks
    28
  - Distributor Rotation and Firing Order
    28
  - Primary Circuit Tests
    29
  - Distributor Resistance Test
    29
  - Distributor Point Dwell
    30
  - Test Ignition Cables
    30
  - Coil
    30
  - Check Fuel Lines and Screens
    30
  - Check Manifold Vacuum
    31
  - Carburetor Adjustments
    31
  - Carburetor View
    32
  - Road Test Vehicle
    33
  - Check Fan Belt
    33
  - Service Diagnosis
    34
  - Poor Fuel Economy
    34
  - Overheating
    34
  - Excessive Oil Consumption
    34
  - Tune-Up Specifications
    35
  - Hurricane F4 Engine
    37
  - Engine Description
    38
- Engine Mountings
  38
- G E N E R a L
  38
- Hurricane F4 Engine Diagrams
  39
- Camshaft
  39
  - Engine Ground Strap
    41
  - Engine Removal
    41
  - Engine Disassembly
    41
  - Remove Distributor
    42
  - Remove Oil Pump
    42
  - Remove Rocker Arm Assemblies
    42
  - Remove Cylinder Head
    42
- Exhaust Manifold
  42
  - Engine Exploded View
    43
  - Remove Piston and Connecting Rod Assemblies
    44
  - Remove Flywheel
    44
  - Remove Crankshaft
    44
- Oil P a N
  44
- Ream Cylinder Bore Ridges. D-L8
  44
  - Engine Inspection and Repair
    45
  - Remove Exhaust Valves and Springs
    45
  - Remove Camshaft
    45
  - Remove Valve Tappets
    45
- E N G I N E I N S P E C T I O N and R E P a I R
  45
- Cleaning
  45
  - Cylinder Bores
    47
  - Pistons, Rings and Connecting Rods
    47
  - Piston Fitting
    48
  - Piston Pin Fitting
    48
  - Checking Connecting Rod Alignment
    48
  - Connecting Rod and Piston
    48
  - Checking Piston and Connecting Rod Alignment
    49
  - Checking Piston Ring Side Clearance
    49
  - Piston Ring Gap
    49
  - Piston Ring Application Chart
    50
  - Crankshaft Inspection and Repair
    50
  - Checking Crankshaft Alignment
    50
  - Checking Main Bearing Journals
    50
  - Checking Connecting Rod Crankpins
    51
- Fitting Crankshaft Main Bearings Using Shim Stock
  51
- Crankshaft Main Bearing Inspection
  51
  - Connecting Rod Bearings
    52
  - Connecting Rod Bearing Inspection
    52
  - Installing Connecting Rod Bearings
    52
  - Camshaft and Bearings
    53
  - Camshaft Front Bearing Replacement
    53
  - Camshaft End Play
    53
  - Timing Gears and Cover
    53
  - Valves, Springs, and Guides Inspection
    54
  - Testing Valve Spring
    54
  - Refacing Valves
    55
  - Valve Seat Inspection and Refacing
    55
  - Exhaust Valve Seat Insert Replacement
    56
  - Valve Guide Replacement
    56
  - Valve Guide Driver
    56
  - Valve Guide Positions
    56
  - Tappets and Cover
    57
  - Crankshaft Rear Bearing Seal
    57
  - Floating Oil Intake
    57
  - Oil Pump
    57
  - Oil Filter, Oil Pan, Oil Pump and Lines Diagram
    58
  - Oil Pan
    59
  - Floating Oil Intake and Pan
    59
  - Oil Pump Diagram
    59
- Flywheel Inspection
  59
- Ring Gear Replacement
  60
- Flywheel Pilot Bushing
  60
  - Flywheel Housing
    60
  - Core Hole Expansion Plug
    60
  - Cylinder Head
    61
  - Rocker Arms
    61
  - Rocker Arm Shaft Disassembly
    61
  - Crankcase Ventilation Valve View
    61
  - Engine Reassembly
    62
  - Install Oil Gallery Plugs
    62
  - Install Tappets
    62
  - Install Camshaft and Thrust Plate
    62
- Inspection
  62
- E N G I N E R E a S S E M B L y
  62
- Install Crankshaft and Bearings
  63
- Check Crankshaft End-Play
  63
  - Valves, Camshaft and Timing Gears Diagram
    63
  - Install Crankshaft Timing Gear
    64
  - Install Crankshaft Rear Bearing Seal
    64
  - Install Front End Plate
    64
  - Install Flywheel
    64
  - Install Flywheel Housing
    65
  - Install Clutch
    65
  - Install Valves and Springs
    65
  - Install Camshaft Timing Gear
    66
  - Install Timing Gear Oil Jet
    66
  - Install Oil Pump
    66
  - Install Pistons and Connecting Rods
    66
  - Install Oil Pan
    67
  - Install Cylinder Head
    67
  - Install Rocker Arm Assembly
    67
  - Install Distributor and Spark Plugs
    67
  - Engine Installation
    68
  - Install Manifold
    68
  - Install Oil Filter Tube
    68
  - Install Water Pump
    68
  - Valve Adjustment
    69
  - Check Valve Timing
    69
  - Positive Crankcase Ventilation
    69
  - Oil Filter
    69
  - Engine Service Diagnosis
    70
  - Lack of Power
    70
  - Low Compression
    70
  - Burned Valves and Seats
    70
  - Hurricane F4 Engine Specifications
    71
- Crankshaft Timing Gear
  72
- Dauntless V-6 Engine
  75
- Cylinder Head
  75
- Distributor D L
  75
- Flywheel
  75
- M a N I F O L D
  75
- Oil Pan
  75
- Oil Pump
  75
- E N G I N E I N S T a L L a T I O N
  75
- Oil Filter
  75
- Cooling F a N and Water Pump
  80
- Carburetor Assembly
  80
- And Inspection D1-65
  93
- Timing Chain and Sprocket Inspection
  95
- E N G I N E R E a S S E M B L y
  95
- Fuel Pump
  109
  - Canister
    111
  - Demand Valve
    111
  - Fuel Evaporative Emission Control System Diagram
    111
  - Fuel Tank
    112
  - Vapor Separator or Expansion Tank
    112
  - Sealed Gas Cap
    112
  - Carburetor
    113
  - Fuel Emission Vent System Inspection Test
    113
  - Fuel Emission Vent System Servicing
    113
  - Float System
    114
  - Float Adjustment
    114
  - Low-Speed System
    114
  - Idle Mixture Adjustment
    114
  - High-Speed System
    115
  - Metering Rod Adjustment
    115
  - Choke System
    116
  - Fast Idle Adjustment
    116
  - Accelerating Pump System
    116
  - Accelerating Pump Maintenance
    116
  - Carburetor Disassembly
    117
  - Carburetor Reassembly
    118
  - Correcting Acceleration Flat Spot
    118
  - Carburetor - Dauntless V-6 Engine
    119
  - Steep-Grade Carburetor Kit
    119
  - Float System (Dauntless V-6)
    120
  - Idle System (Dauntless V-6)
    120
  - Main Metering System (Dauntless V-6)
    120
  - Power System (Dauntless V-6)
    121
  - Accelerator Pump System (Dauntless V-6)
    121
  - Choke System (Dauntless V-6)
    122
  - Carburetor Removal (Dauntless V-6)
    122
  - Air Horn Body Removal and Disassembly (Dauntless V-6)
    122
  - Throttle Body Removal and Disassembly (Dauntless V-6)
    122
  - Throttle Body Assembly (Dauntless V-6)
    123
  - Fuel Bowl Body Assembly (Dauntless V-6)
    123
  - Air Horn Body Assembly (Dauntless V-6)
    123
  - External Carburetor Adjustment (Dauntless V-6)
    124
  - Accelerator Pump Adjustment (Dauntless V-6)
    124
  - Curb Idle Speed and Mixture Adjustments (Dauntless V-6)
    124
  - Float Drop Adjustment
    124
  - Fuel Pump (Double-Action) - Hurricane F4 Engine
    125
  - Fast Idle Adjustment (Dauntless V-6)
    125
  - Dash Pot Adjustment
    125
  - Fuel Pump Disassembly
    126
  - Fuel Pump (Single-Action) - Hurricane F4 Engine
    127
  - Fuel Pump Assembly
    127
  - Vacuum Pump
    127
  - Vacuum Booster Check
    127
  - Fuel Pump Removal
    128
  - Fuel Pump Disassembly (Hurricane F4)
    128
  - Fuel Pump Cleaning and Inspection
    128
  - Fuel Pump Reassembly
    128
  - Fuel Pump Installation (Hurricane F4)
    129
  - Fuel Pump - Dauntless V-6 Engine
    130
  - Air Cleaner
    131
  - Accelerator Linkage
    131
  - Fuel Tank and Fuel Lines
    131
  - Fuel Tank Removal
    132
  - Fuel Tank Installation
    132
  - Accelerator Linkage - V-6 Engine
    132
  - Fuel Tank Cap
    133
  - Fuel Gauge Float Unit
    133
  - Fuel Lines
    133
  - Fuel System Service Diagnosis
    134
  - Engine Hesitates on Acceleration
    134
  - Engine Stalls - Won't Idle
    134
  - Fuel System Service Specifications
    135
  - Exhaust System
    137
  - Exhaust System Maintenance Requirements
    139
  - Exhaust System Servicing
    140
  - Exhaust Manifold Installation
    140
  - Heat Control Valve Replacement
    140
  - Exhaust System Specifications
    141
  - Exhaust Pipe Replacement
    141
  - Muffler Removal and Replacement
    141
  - Tail Pipe Removal and Replacement
    141
  - Exhaust Emission Control System
    143
  - Air Pump
    143
  - Pump Air Filter
    143
  - Air Injection Tubes
    143
  - Exhaust Emission Control System Maintenance
    144
  - Carburetor Idle Setting
    144
  - Removal of Major Units of the Exhaust Emission Control System
    145
  - Anti-Backfire Diverter Valve
    145
  - Check Valve
    145
  - Air Distribution Manifold and Injection Tubes
    145
  - Exhaust Emission Control System Diagnosis Guide
    146
  - Exhaust Emission Control System Maintenance Chart
    147
  - Exhaust Emission Control System Specifications
    147
  - Data Tag
    148
  - Exhaust Emission Control System (Dauntless V-6 Engine)
    149
  - Heaterd Air System (Dauntless V-6)
    149
  - Exhaust Emission Control System (Dauntless V-6) Maintenance
    151
  - Testing Thermo Air Cleaner Operation
    151
  - Carburetor Air Cleaner - Dry Type
    153
  - Positive Crankcase Ventilator Valve
    154
  - Replacement of Vacuum Motor
    154
  - Air Delivery Manifold
    155
  - Anti-Backfire Valve
    155
  - Replacement of Air Cleaner Sensor
    155
  - Removing the Major Units from the Exhaust Emission Control System
    156
  - Distributor
    156
  - Intake Manifold
    156
  - Air Pump Removal
    156
  - Anti-Backfire Valve Removal
    157
  - Air Distribution Manifold and Injection Tubes Removal
    157
  - Cooling System
    161
  - Coolant Flow Diagram
    161
  - Cooling System Components View
    162
  - Radiator
    164
  - Filling Cooling System
    164
  - Draining Cooling System
    164
  - Radiator Pressure Cap
    164
  - Radiator Removal and Replacement
    165
  - Radiator Hoses and Heater Hoses
    165
  - Pressure Testing Cooling System
    165
  - Cylinder Block
    166
  - Thermostat
    166
  - Temperature Sending Unit
    166
  - Water Pump Inspection
    167
  - Water Pump Disassembly
    167
  - Water Pump Reassembly
    167
  - Antifreeze Solutions
    168
  - Inhibited Coolant Solutions
    168
  - Fan Belt
    168
  - Engine Overheating
    169
  - Cooling System Service Diagnosis
    170
  - Cooling System Specifications
    170
  - Antifreeze Chart
    170
  - Loss of Cooling Liquid
    170
  - Electrical System
    171
  - Battery
    172
- H - L
  172
  - Primary Circuit
    173
  - Ignition System
    173
  - Secondary Circuit
    174
  - Alternator Charging System
    174
  - Starting System
    174
  - Wiring Diagrams
    175
  - Prestolite Distributor
    178
  - Distributor Cap
    178
  - Rotor
    178
  - Condenser
    179
  - Distributor Points
    180
  - Governor Mechanism
    181
  - Distributor Removal
    181
  - Prestolite Distributor Disassembly
    181
  - Delco Distributor
    182
  - Distributor Inspection
    182
  - Installation and Ignition Timing
    182
  - Ignition Coil
    182
  - Centrifugal Advance
    184
  - Distributor Removal (Delco)
    184
  - Distributor Disassembly (Delco)
    184
  - Distributor Parts Cleaning and Inspection (Delco)
    185
- 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
  185
  - Distributor Reassembly (Delco)
    186
  - Distributor Installation and Timing (Delco)
    186
  - Coil - V6 Engine
    187
  - Ballast Resistor
    187
  - Spark Plugs
    187
  - Generator - F4 Engine
    188
  - Generator Maintenance
    188
  - Generator Disassembly
    188
  - Armature
    188
  - Field Coils
    189
  - Brush Holders
    189
  - Assembling Generator
    189
  - Generator Exploded View
    189
  - Current-Voltage Regulators
    190
  - Circuit Breaker
    190
  - Voltage Regulator
    190
  - Current-Limiting Regulator
    191
  - Regulator Inspection
    191
  - Regulators Testing
    192
  - Low Charging Rate with a Fully Charged Battery
    192
  - High Charging Rate with a Fully Charged Battery
    192
  - Cleaning of Contacts
    193
  - Low Battery and a Low or no Charging Rate
    193
  - Alternator Precautions
    195
  - Alternator Charging System Service
    195
  - Alternator in Vehicle Tests
    195
- A L T E R N a T O R C H a R G I N G S y S T E M
  195
- Alternator Output Test
  195
- Isolation Diode Test
  195
  - Isolation Diode Check
    196
  - Alternator Output Test
    196
  - Regulator Test
    196
  - Removal and Installation of Voltage Regulator
    197
  - Alternator Field Circuit Test
    197
  - Brush Removal and Inspection
    197
  - Brush Insulation and Continuity Test
    197
  - Alternator Bench Tests
    198
  - Alternator Removal
    198
  - Rotor Tests - Bench
    198
- Alternator Disassembly
  198
- A L T E R N a T O R B E N C H T E S T S
  198
- A L T E R N a T O R R E M O V a L
  198
  - Alternator Inspection
    199
  - Alternator Exploded View
    199
- H - 8 1 . G E N E R a L I N S P E C T I O N
  199
- Out-Of-Circuit Rotor Test
  200
- Out-Of-Circuit Stator Leakage Test
  200
  - Stator Coil Leakage and Continuity Test
    200
  - Out-Of-Circuit Rectifier Diode Test
    201
  - Assembling Alternator
    201
  - Alternator Installation
    201
  - Starting System Service
    202
  - Prestolite Starting Motor
    202
  - Ignition Switch Removal
    202
  - Ignition Switch Installation
    202
  - Starting Motor Maintenance
    203
  - Commutator
    203
  - Starting Motor Removal and Installation
    203
- Brushes
  203
  - Prestolite Starting Motor Exploded View
    204
  - Brush Holder Inspection
    205
  - Starting Motor Reassembly
    205
  - Starting Motor Bench Test
    206
  - Bendix Folo-Thru Drive (Prestolite)
    206
  - Lubrication of Folo-Thru Drive
    206
  - Starter Solenoid Switch (Prestolite)
    207
  - Delco Starting Motor Diagram
    207
  - Starting Motor - Delco Dauntless V-6 Engine Disassembly and Inspection
    208
  - Starting Motor - Delco Dauntless V-6 Engine Reassembly
    209
  - Installing Pinion Stop Retainer and Thrust Collar on Armature Shaft
    210
  - Measuring Pinion Clearance
    210
  - Electrical Instruments
    211
  - Starting Motor No-Load Test
    211
  - Locked Armature Test
    211
  - Fuel Gauge
    211
  - Lighting System
    212
  - Testing Indicators and Gauges
    212
  - Main Light Switch
    212
  - Headlight Dimmer Switch
    213
  - Stop Light Switch
    213
  - Head Lamp Replacement
    213
  - Head Lamp Aiming Preparation
    214
  - Aiming Head Lamps
    215
  - Parking and Turn Signal Light
    215
  - Tail, Stop and Turn Signal Light
    215
  - Backup Lights
    215
  - License Plate Light
    216
  - Horn
    216
  - Directional Signals
    216
  - Hazard Warning Lights
    217
  - Marker Lights and Reflector Assembly
    217
  - Two-Speed Wiper Motor
    217
  - Wiper Troubleshooting in Vehicle
    217
  - Wiper Troubleshooting on Bench
    218
  - Disassembly/Reassembly of Two-Speed Wiper Motor
    218
  - Cleaning of Two-Speed Wiper Motor
    218
  - No Load Testing
    218
  - Major Electrical Component Replacement
    219
  - Two-Spee Wiper Motor Exploded View
    219
  - Electrical System Service Diagnosis
    220
  - Battery Discharged
    220
  - Alternator Problems
    220
  - Generator Problems
    220
  - Starting Motor - Slow Starter Speed
    221
  - Distributor - Hard Starting
    221
  - Lights Problems
    221
  - Generator Fails to Charge
    221
  - Horn Fails to Sound
    222
  - Horn Sounds Unsatisfactory Tone
    222
  - Electrical Specifications
    223
  - Clutch
    225
- 1-1. General
  226
- 1-2. Clutch Maintenance
  226
- 1-3. Clutch Pedal Linkage and Adjustment
  226
- 1-4. Clutch - Hurricane F4 Engine
  227
- 1-6. Clutch Pressure Plate and Disc Inspection
  227
- Clutch Fitxure
  227
- 1-5. Clutch Removal
  227
  - Pilot Bushing Inspection and Replacement
    228
  - Clutch Installation
    228
  - Clutch - Dauntless V6 Engine
    229
  - Clutch Removal (Dauntless V6)
    229
  - Clutch Inspection (Dauntless V6)
    229
- 1-12. Clutch Inspection
  229
- Diaphragm Spring Type
  229
- 1-27. Clutch Installation
  235
  - Control Lever and Tube Diagram
    236
  - Clutch Service Diagnosis
    237
  - Clutch Specifications
    237
  - Clutch Dragging
    237
  - Clutch Rattling
    237
  - Three-Speed Transmission
    239
  - Transmission Shifting Control
    239
  - Transmission Remote Control Adjustment
    239
  - Removal of Remote Control
    239
  - Transmission Removal
    240
  - Reassembly of Remote Control
    240
  - Three-Speed Transmission Diagram
    241
  - Separating Transmission and Transfer Case
    242
  - Transmission Disassembly
    245
  - Transmission Interlocking Sleeve Inspection
    246
  - Shift Lock Plate View
    246
  - Countershaft Bearing Spacers View
    246
  - Interlock Sleeve Clearance View
    246
  - Transmission Inspection
    247
  - Transmission Reassembly
    247
  - Transmission - T96
    248
  - Transmission Cleaning and Inspection
    248
  - Cane Shift Control Housing Assembly View
    250
  - T14A Transmission
    251
  - Transfer Case Drive Gear Assembly View
    251
  - Removing Main Drive Gear Bearing
    251
  - Removing Mainshaft Bearing
    251
  - Removing-Installing Mainshaft Gear Assembly
    252
  - Removing-Installing Lockplate
    252
  - Removing-Installing Countershaft
    252
  - Removing-Installing Reverse Idler Gear
    252
  - Disassembly Synchronizer Assemblies
    253
  - Second-Third Synchronizer Assembly
    253
  - Transmission Reassembly - T14A
    254
  - Countershaft Gear Bearing Arbor View
    254
  - Countershaft Bearings and Spacers Installed View
    254
  - Lockplate Installation
    254
  - Main Drive Gear Roller Bearings Installed View
    255
  - Installing Main Drive Gear Assembly
    255
  - Installing Main Drive Gear Bearing
    255
  - Installing Main Shaft Bearing
    255
  - Installing Main Drive Gear Bearing Retainer
    256
  - Mainshaft Gear Train - Neutral
    256
  - Installing Cane Shift Cover Assembly
    256
  - Transmission Service Diagnosis
    257
  - Transmission Specifications
    257
  - Four-Speed Transmission
    259
  - Four-Speed Transmission Removal
    260
  - Four-Speed Transmission Main Drive Gear View
    260
  - Four-Speed Transmission Main Shaft View
    260
  - Four-Speed Transmission Disassembly
    261
  - Four-Speed Transmission Control Parts View
    262
  - Four-Speed Transmission Control Housing Disassembly
    263
  - 4-Speed Transmission Reassembly
    263
  - Assembling Second Speed Synchronizer
    263
  - Four-Speed Transmission Control Housing Reassembly
    264
  - Snap Ring and Thrust Washer Installation
    264
  - Second-Speed Gear Assembly
    264
  - Installing 4-Speed Transmission
    265
  - Adapter Plate Oil Seal
    265
  - Four-Speed Transmission Service Diagnosis
    266
  - Four-Speed Transmission Specifications
    266
  - Transfer Case Description
    267
  - Transfer Case Removal
    267
  - Transfer Case View - Two Shift Lever
    268
  - Transfer Case View - One Shift Lever
    269
  - Transfer Case Disassembly
    270
  - Universal Joint Flange Puller View
    270
  - Transfer Case Shift Linkage View
    270
  - Bearing Cone Removing Wedge View
    270
  - Front Bearing Cap Disassembly
    271
  - Rear Cap Disassembly
    271
  - Bearing Cup Removing Ring View
    271
  - Shift Rod Oil Sealer Installer View
    271
  - Transfer Case Reassembly
    272
  - Thrust Washer Pilot View
    272
  - Output Shaft Snap Ring Installer View
    272
  - Output Shaft Oil Seal Driver View
    272
  - Transfer Case Service Diagnosis
    273
  - Transfer Case Specifications
    273
  - Transfer Case Linkage Adjustment
    273
  - Propeller Shafts and Universal Joints
    275
  - Needle Bearing and Trunnion Universal Joint
    275
  - Snap Ring Type Disassembly
    275
  - Universal Joints View
    275
  - Propeller Shafts and Universal Joints Specifications
    276
  - Snap Ring Type Assembly
    276
  - U-Bolt Type Disassembly
    276
  - U-Bolt Type Assembly
    276
  - 4-Wheel Drive Front Axle
    277
  - Front Axle Removal
    278
  - Hub Cap Puller View
    278
  - Front Axle Shaft Removal
    279
  - Axle Shaft Universal Joint Service
    279
  - Removing and Overhauling Differential
    279
  - Axle Shaft Drive Flange Puller View
    279
  - Cardan Cross Universal Joint View
    280
  - Steering Knuckle and Wheel Bearings View
    280
  - Axle Shaft Installation
    281
  - Steering Knuckle Service
    281
  - Reassemble and Bearing Preload
    281
  - Replacing Steering Knuckle Oil Seal
    281
  - Front Axle Installation
    282
  - 2-Wheel-Drive Front Axle
    282
  - Removal of Solid Front Axle
    282
  - Front Steering Knuckle View
    282
  - Front Axle View
    283
  - Steering Knuckle Pin Replacement
    284
  - Front Axle Service Diagnosis
    285
  - Low Speed Shimmy of Wheel Fight
    285
  - High Speed Shimmy of Wheel Flight
    285
  - Wandering
    285
  - Front Axle Specifications
    286
  - Rear Axle Description
    287
  - Rear Axle Shaft Removal and Installation
    287
  - Axle Model Identification
    287
  - Ratio, Powr-Lok and Trac-Lok Differential Identification
    287
  - Semifloating Rear Axle - Tapered Shaft View
    288
  - Wheel Hub Puller View
    288
  - Rear Axle Shaft Removal (Semi-Float-Flanged Shaft)
    289
  - Semi-Float Rear Axle Assembly - Flanged Shaft View
    289
  - Unit Bearing
    290
  - Removing Flanged Axle Shaft
    290
  - Lubricating Unit Bearing
    291
  - Unit Bearing Removal
    291
  - Rear Axle Shaft and Bearing Installation (Semi-Float-Flanged Shaft)
    292
  - Notching Bearing Retaining Ring
    292
  - Removing Axle Shaft Bearing
    292
  - Rear Axle Assembly
    293
  - Rear Axle Removal
    293
  - Axle Shaft Bearing Installed View
    293
  - Removing Pinion Shaft Oil Seal
    293
  - Differential Case Disassembly
    294
  - Differential Carrier Spreader Tool View
    294
  - Removing Lock Pin
    294
  - End Yoke Holding Wrench View
    294
  - Pinion and Differential Case Bearing Removal
    295
  - Pinion Bearing Cup Removal, Cleaning, Inspection
    295
  - End Yoke Puller View
    295
  - Removing Cone and Roller with Puller
    295
  - Pinion Installation and Adjustment
    296
  - Pinion Adjusting Fixture
    297
  - Setting Pinion Gauge
    297
  - Checking Pinion Adjustment
    297
  - Differential Case Reassembly
    298
  - Differential Shim Pack Locations
    298
  - Adjustment of Differential Side Gears
    299
  - Adjustment of Differential Bearing Preload and Ring Gear Backlash
    299
  - Checking Side Gear Clearance
    299
  - Differential Bearing Driver
    299
  - Installing Inner Oil Seals
    300
  - Checking Ring Gear Backlash
    300
  - Gear Tooth Contact
    300
  - Powr-Lok Differential
    301
  - Trouble Symptoms and Possible Causes
    301
  - Pinion Shaft Oil Seal Installer
    301
  - Powr-Lok Differential Disassembly and Reassembly
    302
  - Plate Assembly Order
    302
  - Trac-Lok Differential Description
    303
  - Trac-Lok Lubrication
    303
  - Trac-Lok Troubleshooting
    303
  - Trac-Lok Differential Disassembly and Reassembly
    303
  - Trac-Lok Inspection
    306
  - Plate and Disc Identification
    307
  - Lubricating Trac-Lok Components
    307
  - Installing Plate Retainer Clips
    307
  - Install Differential Case on Axle Shaft
    307
  - Positioning Gear Rotating Tool
    308
  - Threading Forcing Screw into Rotating Tool
    308
  - Rotating Pinion Mate Gears into Position
    308
  - Installing Pinion Mate Washers
    308
  - Installing Rear Axle
    309
  - Complete Trac-Lok Assembly Replacement
    309
  - Installing Cross Pin
    309
  - Torquing Ring Gear Screws
    309
  - Rear Axle Service Diagnosis
    310
  - Backlash
    310
  - Rear Wheel Noise
    310
  - Axle Noisy on Pull and Coast
    310
  - Rear Axle Specifications
    311
  - Steering System
    313
  - Steering Linkage View
    313
  - Steering Gear Function
    314
  - Steering Linkage
    314
  - Steering Column and Gear Alignment
    314
  - Steering Gear Adjustment
    315
  - Front Wheel Alignment Adjustment
    315
  - Front Wheel Toe-In
    315
  - Toe-In Adjustment
    316
  - Front Wheel Camber
    316
  - Axle Caster
    316
  - Front Wheel Turning Angle
    317
  - Steering Knuckle Arm
    317
  - Front Wheel Shimmy
    317
  - Steering Linkage Service
    318
  - Steering Connecting Rod (Drag Link)
    318
  - Tie Rod
    318
  - Tie Rod Removal
    319
  - Steering Bellcrank Service
    319
  - Steering Column and Wheel Service
    320
  - Steering Gear Service
    320
  - Bellcrank Support Bracket Rivet Replacement
    320
  - Removal of Steering Gear
    320
  - Disassembly of Steering Gear
    321
  - Reassembly of Steering Gear
    321
  - Installation of Steering Gear
    321
  - Steering Wheel Insatallation
    321
  - Steering System Service Diagnosis
    322
  - Steering Specifications
    322
  - Brakes
    323
  - Master Cylinder - Double Safety Brake System
    323
  - Parking Brakes
    324
  - Parking Brake Linkage
    324
  - Transmission Brake
    325
  - Brake Maintenance
    325
  - Brake Service
    325
  - Bleeding Brakes
    326
  - Brake Hoses
    326
  - Brake Pedal Adjustment
    326
  - Hand Brake
    327
  - Parking Brake Adjustment
    327
  - Transmission Brake Adjustment
    327
  - Relining Transmission Brake
    327
  - Self-Adjusting Wheel Brake Units
    328
  - Relining Wheel Brakes
    328
  - Brake Shoe Removal
    328
  - Brake Shoe Inspection
    329
  - Brake Shoe Installation
    329
  - Wheel Hub Oil Seal Driver
    329
  - Standard Front Wheel Brake Assembly with Link Type Adjuster
    329
  - Installing the Rear Brake Shoes
    330
  - Brake Shoe Initial Adjustment
    331
  - Master Cylinder Reconditioning - Dual System
    331
  - Master Cylinder Reassembly
    332
  - Double Safety Master Cylinder View
    332
  - Removing Tube Seats
    332
  - Brakes Troubleshooting
    333
  - Wheel Cylinder Reconditioning
    333
  - Squeaky Brakes
    333
  - Rattles in Brakes
    333
  - Brakes Service Diagnosis
    334
  - Brakes Drag
    334
  - Brake Grabs - Vehicle Pulls to One Side
    334
  - Excessive Pedal Pressure
    334
  - Wheels
    335
  - Wheel Balancing
    335
  - Front Wheel Attaching Parts - 4-Wheel Drive
    335
  - Wheel Bearing Service
    336
  - Rear Wheel Attaching Parts - 4-Wheel Drive Tapered Axle
    336
  - Rear Wheel Attaching Parts - 2-Wheel-Drive-Tapered Axle
    336
  - Checking Front Wheel Bearings
    337
  - Front Wheel Bearing Adjustment
    337
  - Rear Wheel Bearing Adjustment - Flanged Axle Shaft
    337
  - Checking Rear Wheel Bearings - Tapered Axle
    337
  - Rear Wheel Mounting - Tapered Axle
    338
  - Brake Drum Service
    338
  - Tire Service
    338
  - Rear Wheel Bearing Adjustment - Tapered Axle
    338
  - Tire Care
    339
  - Tire Removal and Installation
    339
  - Tire Wear Pattern
    339
  - Underinflation/Overinflation
    339
  - Wheel and Tire Specifications
    340
  - Tire Rotation
    340
  - Frame
    341
  - Checking Frame Alignment
    341
  - Frame Assembly Diagram
    342
  - Frame Assembly Measurements
    342
  - Frame Specifications
    343
  - Frame Dimensions
    343
  - Straightening Frame
    343
  - Draw Bar
    343
  - Springs and Shock Absorbers
    345
  - Spring Shackles
    345
  - Pivot Bolts
    346
  - Remove Spring
    346
  - Install Spring
    346
  - U-Shackles
    347
  - Shock Absorbers
    348
  - Spring Pivot Bolt View
    348
  - Front Spring Shackle View
    348
  - Spring Specifications
    349
  - Shock Absorber Specifications
    349
  - Body
    351
  - Windshield
    352
  - Windshield Glass
    354
  - Canvas Tops
    354
  - Vehicle Controls View
    354
  - Tail Gate Assembly View
    354
  - Care of Fabric Tops
    355
  - Brake and Clutch Pedal Pads
    355
  - Front Seat Adjustment
    355
  - Passenger Seat Safety Catch
    356
  - Miscellaneous
    357
  - Extra Equipment
    357
  - Governor Adjustment
    357
  - Novi Governor Operation
    357
  - Pintle Hook Installation
    358
  - Front Bumper Weight
    358
  - Fresh Air Heater and Defroster
    359
  - Special Tools
    360
  - Engine Torque Specifications
    362
  - Special Chassis Torque Specifications
    364
  - Chassis and Body Bolt Torque Chart
    364
  - Draw Bar Pull
    365
  - Power Take-Off Shaft and Vehicle Ground Speeds
    366
  - Spline Shaft Horsepower
    367
  - Pulley Speeds
    367
  - List of Abbreviations
    369
  - Alphabetical Index
    371

Advertisement

Advertisement

Related Products

Kaiser-Jeep Categories

More Kaiser-Jeep Manuals