Jeep CJ Rebuilder's Manual 1972-1986: CJ-5, CJ-6, CJ-7, CJ-8 Scrambler

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Item # BEN-01517  ISBN: 0837601517




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Models Covered: Jeep CJ-5, CJ-6, CJ-7, and CJ-8/Scrambler, 1972-1986.

The AMC-era CJ Jeep vehicle is a four-wheel drive icon. Built from 1972-1986, these models offer advanced technology and exceptional off-pavement ability. Today, they remain top contenders on the roughest trails and byways, providing the rugged utility that owners expect from the Jeep brand.

If working on your Jeep vehicle engine, transmission, transfer case, axles, steering system, electrical system or body tub has seemed just beyond your skill level, here is the fix! Moses Ludel, Jeep vehicle expert, automotive instructor and author of the Jeep Owner's Bible, demystifies the most complex service procedures.

At his Camp Jeep workshops, Moses discovered that hobbyists and professional Jeep vehicle mechanics alike want heavily illustrated, step-by-step 'how-to' manuals. For the Jeep vehicle owner who finds the typical workshop manual impossible to decipher, Moses Ludel breaks ground with this book. The author and photographer/illustrator of more than 2,500 magazine tech articles and five popular Owner's Bible books, Moses undertook the Jeep CJ Rebuilder's Manual to meet the needs of Jeep vehicle owners and restorers. Using a pictorial, step-by-step format, this ambitious effort launches a series of 'how-to' rebuild manuals with a photograph marking each technical step.

Moses begins with the disassembly of an AMC-era CJ, photographing each step in the process. He then disassembles and rebuilds each powertrain, geartrain and axle component of the vehicle—again under the close-up scrutiny of his camera! Recognizing the performance expectations of contemporary owners, Moses Ludel then shifts to the popular upgrades that distinguish the ultimate trail-running CJ models. Each step is thoroughly explained, and even the most complex mechanical procedures can be readily understood.

Table of Contents

INTRODUCTION

1. DISASSEMBLING YOUR JEEP
A Place to Start | Front Clip and Body Tub Removal | Disassembly of the Chassis

2. ENGINE REBUILDING
Jeep Engines | Choosing the Right Engine Type | Typical Jeep Engine Rebuild | Assembling a Crate/Remanufactured Engine | Engine Peripherals and Accessories | Monitoring and Protecting the New Engine

3. TRANSMISSION and CLUTCH
Rebuilding the Transmission | T-18 Four Speed Rebuild | Retrofitting a T-18 Four-Speed | Ultimate Manual Transmission Retrofits | Clutch Service and Replacement | Clutch Linkage and Upgrades | Clutch Data and Torque Settings

4. TRANSFER CASE and OVERDRIVE
General | "Spicer 20" Rebuild Steps | The Dana 300 Rebuild | Assembling the Dana 300 | Borg-Warner's Jeep "Quadra-Trac"

5. AXLE REBUILDING and UPGRADES
General | Front Axle Disassembly | Rebuilding the Front Axle Assembly | Steering Knuckle Service | Using a Hydraulic Press to Install Ball-Joints | Axle Shaft U-Joints and Shaft Installation | Rear Axle Service and Upgrades | Disassembling the Spicer/Dana 44 Axle | Installing an Aftermarket Locker | Full-Floating Rear Axle Shaft Conversion | AMC Model 20 Axle Rebuild | AMC Model 20 Axle Shaft Installation | Driveline Service and Upgrades | Installing U-Joints | Custom Driveshaft Upgrades | Axle Data and Specifications Section

6. FRAME, SUSPENSION, and BODY REPAIR
General | Frame Repairs | Building a Transmission/Frame Crossmember | Spring, Shackles and Bushings | Body Modifications and Metal Parts Restoration Tips | Sheet Metal Restoration Basics | Frame Measurement Methods

7. STEERING and BRAKE SERVICE
General | The AMC/Jeep Steering Systems | Steering Linkage and Columns | Brake System Service and Upgrades | OEM Drum Brake Service | Pedal and Brake Adjustment Tips | Disc Brake Conversions | Warn's Wheel Hub Bearing Adjustment Method | OEM Wheel Bearing Service and Adjustment | Installing New Wheel Cylinders and Brake Shoes | Installing Calipers, Brake Pads and Front Hoses | Master Cylinder Installation | Upgrading the Hydraulic System | Safe Brake Proportioning and Metering

8. ELECTRICAL and IGNITION SYSTEM UPGRADES
General | Ignition System and Upgrades | Breaker Point Ignition Fundamentals "101" | Jeep Ignition Performance Upgrade | OEM Wiring Diagrams

9. FUEL and EXHAUST SYSTEMS
General | Carter One-Barrel Carburetors | Engine Air Intake and Filtration | The "BBD" Carter Two-Barrel Carburetor | Mopar's MPI/EFI Conversion Kit for the 4.2L Inline Six | Exhaust Systems

10. ACCESSORIES and SAFETY EQUIPMENT
General | What's Next?

Appendix | Index | About the Author | Acknowledgments

Jeep CJ Rebuilder's Manual 1972-1986: CJ-5, CJ-6, CJ-7, CJ-8 Scrambler