Home Jeep Repair Jeep CJ Rebuilder»s Manual: 72-86

Table of Contents

Jeep® CJ Rebuilder
Disassembling Your Jeep,
see Chapter 1
Jeep® CJ Rebuilder
Engine Rebuilding,
see Chapter 2
Jeep® CJ Rebuilder
Transmission and Clutch, see Chapter 3
Jeep® CJ Rebuilder
Transfer Case,
see Chapter 4
Jeep® CJ Rebuilder
Axle Rebuilding and Upgrades, see Chapter 5
Jeep® CJ Rebuilder
Electrical and Ignition System Upgrades,
see Chapter 8
Jeep® CJ Rebuilder
Fuel and Exhaust Systems,
see Chapter 9
Jeep® CJ Rebuilder
Accessories and Safety Equipment,
see Chapter 10
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
?Spicer 20' Rebuild Steps
The Dana 300 Rebuild
Assembling the Dana 300
Borg-Warner's Jeep ?Quadra-Trac'
5 Axle Rebuilding and Upgrades
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
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
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
Ignition System and Upgrades
Breaker Point Ignition Fundamentals ?101'
Jeep Ignition Performance Upgrade
OEM Wiring Diagrams
9 Fuel and Exhaust Systems
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
What's Next?
A Appendix


About the Author, Acknowledgments