Jeep CJ Rebuilder's Manual 1972-1986: CJ-5, CJ-6, CJ-7, CJ-8 Scrambler
In this popular 1972-1986 Jeep CJ Rebuilder's Manual, renowned author and Jeep expert Moses Ludel, brings the "secrets" of how to fix your Jeep down to Earth.
Ludel understands how DIY mechanics think, and so this manual is a heavily illustrated book, with step-by-step sequences that cover the whole gamut; from basic maintenance all the way to advanced service procedures.
Jeep vehicles built by AMC are true 4x4 icons, offering exceptional off-road capabilities. To this day, these four-wheel drives remain popular among Jeep owners who want reliable transportation, from paved roads to the roughest trails across the land.
Models covered by this manual include 1972-1986:
Jeep CJ-5
Jeep CJ-6
Jeep CJ-7
Jeep CJ-8
Jeep Scrambler
Book Excerpt: Jeep CJ Rebuilder's Manual 1972-1986: CJ-5, CJ-6, CJ-7, CJ-8 Scrambler
THE V-8 WATER PUMP CHALLENGE
For those CJ owners who like power and power options, there is always the AMC 360 or 401 V-8 engine swap. These gutsy, reliable engines are, for the most part, easy to service. The spark plugs are readily accessible, the distributor is right at the front -- even the oil pump is within easy reach, outside the crankcase and mounted at the base of the timing cover. If you like an engine with a lot of power options, however, you also need to know that one service item is not very easy to reach; the water pump.
Our '87 Grand Wagoneer's original water pump lasted 134,000 miles before giving up. This is a good deal of use as the engine has power everything, including power steering and air conditioning. The V-belt load on the water pump bearings is heavy, yet the pump worked unflinchingly for a very long time.
I set aside a weekend morning to change the water pump. Thinking in terms of a two-hour job. I thought for sure that my air tools and hoist would make haste of this chore. Was I in for a surprise!
AXLE REBUILDING AND UPGRADES
GENERAL
The front axles of 1972-1986 CJs are rugged Dana 30 units. Incorporating a live, hypoid axle system with open steering knuckle joints, "solid axles" have proven exceptionally versatile and durable. Both drum type (1972 to early '77) and disc (late 1977 to '86) brakes have been used with the Dana 30 front axle.
A hypoid (solid) rear axle is common to all CJs. The '72-'75 models and some 1986 models feature a rugged Dana 44 rear axle. AMC's own Model 20 axles, used in 1976-1986 models, have proven very reliable as well. The Dana 44 has an 8.75" ring gear diameter, and the Model 20 ring gear is slightly larger at 8.875".
NOTE: The AMC Model 20 axle has received criticism from some owners. This, however has more to do with the axle shaft/wheel hub design than any issue with the axle's differential or housing stamina. In the AMC Model 20 section, I address the axle shaft/hub issue.
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
