Jeep Cj Rebuilder's Manual, 1972-1986: Mechanical Restoration, Unit Repair and Overhaul Performance Upgrades for Jeep Cj-5, Cj-6, Cj-7, and Cj-8/Scrambler

by Ludel, Moses

• ISBN13: 9780837601519
• ISBN10: 0837601517
• Format: Paperback
• Copyright: 2003-10-01
• Publisher: Bentley Pub

Table of Contents

Introduction	v
Disassembling Your Jeep	1	(22)
A Place to Start	2	(7)
Front Clip and Body Tub Removal	9	(7)
Disassembly of the Chassis	16	(7)
Engine Rebuilding	23	(36)
Jeep Engines	24	(1)
Choosing the Right Engine Type	25	(4)
Typical Jeep Engine Rebuild	29	(13)
Assembling a Crate/Remanufactured Engine	42	(8)
Engine Peripherals and Accessories	50	(6)
Monitoring and Protecting the New Engine	56	(3)
Transmission and Clutch	59	(66)
Rebuilding the Transmission	60	(1)
T-18 Four Speed Rebuild	61	(20)
Retrofitting a T-18 Four-Speed	81	(6)
Ultimate Manual Transmission Retrofits	87	(25)
Clutch Service and Replacement	112	(6)
Clutch Linkage and Upgrades	118	(3)
Clutch Data and Torque Settings	121	(4)
Transfer Case and Overdrive	125	(84)
General	126	(2)
'Spicer 20' Rebuild Steps	128	(29)
The Dana 300 Rebuild	157	(13)
Assembling the Dana 300	170	(33)
Borg-Warner's Jeep 'Quadra-Trac'	203	(6)
Axle Rebuilding and Upgrades	209	(114)
General	210	(3)
Front Axle Disassembly	213	(13)
Rebuilding the Front Axle Assembly	226	(15)
Steering Knuckle Service	241	(7)
Using a Hydraulic Press to Install Ball-Joints	248	(2)
Axle Shaft U-Joints and Shaft Installation	250	(8)
Rear Axle Service and Upgrades	258	(3)
Disassembling the Spicer/Dana 44 Axle	261	(2)
Installing an Aftermarket Locker	263	(8)
Full-Floating Rear Axle Shaft Conversion	271	(3)
AMC Model 20 Axle Rebuild	274	(24)
AMC Model 20 Axle Shaft Installation	298	(11)
Driveline Service and Upgrades	309	(1)
Installing U-Joints	310	(4)
Custom Driveshaft Upgrades	314	(4)
Axle Data and Specifications Section	318	(5)
Frame, Suspension, and Body Repair	323	(42)
General	324	(4)
Frame Repairs	328	(8)
Building a Transmission/Frame Crossmember	336	(4)
Spring, Shackles and Bushings	340	(9)
Body Modifications and Metal Parts Restoration Tips	349	(6)
Sheet Metal Restoration Basics	355	(8)
Frame Measurement Methods	363	(2)
Steering and Brake Service	365	(70)
General	366	(1)
The AMC/Jeep Steering Systems	366	(6)
Steering Linkage and Columns	372	(7)
Brake System Service and Upgrades	379	(1)
OEM Drum Brake Service	380	(2)
Pedal and Brake Adjustment Tips	382	(2)
Disc Brake Conversions	384	(10)
Warn's Wheel Hub Bearing Adjustment Method	394	(5)
OEM Wheel Bearing Service and Adjustment	399	(8)
Installing New Wheel Cylinders and Brake Shoes	407	(12)
Installing Calipers, Brake Pads and Front Hoses	419	(3)
Master Cylinder Installation	422	(3)
Upgrading the Hydraulic System	425	(6)
Safe Brake Proportioning and Metering	431	(4)
Electrical and Ignition System Upgrades	435	(36)
General	436	(14)
Ignition System and Upgrades	450	(2)
Breaker Point Ignition Fundamentals '101'	452	(8)
Jeep Ignition Performance Upgrade	460	(3)
OEM Wiring Diagrams	463	(8)
Fuel and Exhaust Systems	471	(80)
General	472	(2)
Carter One-Barrel Carburetors	474	(14)
Engine Air Intake and Filtration	488	(1)
The 'BBD' Carter Two-Barrel Carburetor	489	(30)
Mopar's MPI/EFI Conversion Kit for the 4.2L Inline Six	519	(25)
Exhaust Systems	544	(7)
Accessories and Safety Equipment	551	(26)
General	552	(22)
What's Next?	574	(3)
A Appendix	577	(20)
Index	597	(6)
About the Author, Acknowledgments	603