Jeep CJ Rebuilder's Manual: 1972 to 1986~CJ5-CJ6-CJ7~Overhaul~Step-by-Step~NEW

Description

Jeep CJ Rebuilder's Manual: 1972 to 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. 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.
TABLE OF CONTENTS
Introduction
v
1.
Disassembling Your Jeep
1
A Place to Start
2
Front Clip and Body Tub Removal
9
Disassembly of the Chassis
16
2.
Engine Rebuilding
23
Jeep Engines
24
Choosing the Right Engine Type
25
Typical Jeep Engine Rebuild
29
Assembling a Crate/Remanufactured Engine
42
Engine Peripherals and Accessories
50
Monitoring and Protecting the New Engine
56
3.
Transmission and Clutch
59
Rebuilding the Transmission
60
T-18 Four Speed Rebuild
61
Retrofitting a T-18 Four-Speed
81
Ultimate Manual Transmission Retrofits
87
Clutch Service and Replacement
112
Clutch Linkage and Upgrades
118
Clutch Data and Torque Settings
121
4.
Transfer Case and Overdrive
125
General
126
'Spicer 20' Rebuild Steps
128
The Dana 300 Rebuild
157
Assembling the Dana 300
170
Borg-Warner's Jeep 'Quadra-Trac'
203
5.
Axle Rebuilding and Upgrades
209
General
210
Front Axle Disassembly
213
Rebuilding the Front Axle Assembly
226
Steering Knuckle Service
241
Using a Hydraulic Press to Install Ball-Joints
248
Axle Shaft U-Joints and Shaft Installation
250
Rear Axle Service and Upgrades
258
Disassembling the Spicer/Dana 44 Axle
261
Installing an Aftermarket Locker
263
Full-Floating Rear Axle Shaft Conversion
271
AMC Model 20 Axle Rebuild
274
AMC Model 20 Axle Shaft Installation
298
Driveline Service and Upgrades
309
Installing U-Joints
310
Custom Driveshaft Upgrades
314
Axle Data and Specifications Section
318
6.
Frame, Suspension, and Body Repair
323
General
324
Frame Repairs
328
Building a Transmission/Frame Crossmember
336
Spring, Shackles and Bushings
340
Body Modifications and Metal Parts Restoration Tips
349
Sheet Metal Restoration Basics
355
Frame Measurement Methods
363
7.
Steering and Brake Service
365
General
366
The AMC/Jeep Steering Systems
366
Steering Linkage and Columns
372
Brake System Service and Upgrades
379
OEM Drum Brake Service
380
Pedal and Brake Adjustment Tips
382
Disc Brake Conversions
384
Warn's Wheel Hub Bearing Adjustment Method
394
OEM Wheel Bearing Service and Adjustment
399
Installing New Wheel Cylinders and Brake Shoes
407
Installing Calipers, Brake Pads and Front Hoses
419
Master Cylinder Installation
422
Upgrading the Hydraulic System
425
Safe Brake Proportioning and Metering
431
8.
Electrical and Ignition System Upgrades
435
General
436
Ignition System and Upgrades
450
Breaker Point Ignition Fundamentals '101'
452
Jeep Ignition Performance Upgrade
460
OEM Wiring Diagrams
463
9.
Fuel and Exhaust Systems
471
General
472
Carter One-Barrel Carburetors
474
Engine Air Intake and Filtration
488
The 'BBD' Carter Two-Barrel Carburetor
489
Mopar's MPI/EFI Conversion Kit for the 4.2L Inline Six
519
Exhaust Systems
544
10.
Accessories and Safety Equipment
551
General
552
What's Next?
574
Appendix
577
Index
597
About the Author, Acknowledgments
603
SOFTCOVER. 11.08" L x 8.5" W (3.11 lbs). 603 pages
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