Jeep Cj Rebuilder's Manual: 1972 To 1986

Overview

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...
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Overview

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 model. Each step is thoroughly explained, and even the most complex mechanical procedures can be readily understood.

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Product Details

  • ISBN-13: 9780837601519
  • Publisher: Bentley Publishers
  • Publication date: 12/28/2003
  • Pages: 612
  • Sales rank: 345,215
  • Product dimensions: 8.50 (w) x 11.00 (h) x 1.10 (d)

Table of Contents

Introduction v
1 Disassembling Your Jeep 1
A Place to Start 2
Front Clip and Body Tub Remova 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
A Appendix 577
Index 597
About the Author, Acknowledgments 603
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