
'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
The
purpose of caster Fig. O-S, is to provide steer
ing stability which
will
keep the front wheels in the
straight
ahead position and also assist in straighten
ing up the wheels when coming out of a
turn.
Caster
of the front wheels is preset. If the angle of
caster,
when accurately measured, is found to be
incorrect,
correct it to the specification given at
the end of this section by either installing new
parts
or installing caster shims
between
the axle
pad
and the springs.
If
the camber and toe-in are correct and it is known
the the axle is not twisted, a satisfactory check
may
be made by testing the vehicle on the road.
Before road testing, make sure all tires are properly
inflated,
being particularly careful that both front
tires are inflated to exactly the same pressure.
If
vehicle turns easily to either side but is
hard
to
straighten out, insufficient caster for easy handling of vehicle is indicated. If correction is necessary, it
can
usually be accomplished by installing shims
between
the springs and axle pads to secure the
desired
result.
0-11-
Front
Wheel
Turning
Angle
When
the front wheels are turned, the inside wheel
on the
turn
travels in a smaller circle than the outside wheel, therefore, it is necessary for the wheels
to toe out to prevent the tire on the inside wheel
frOm
being scuffed sideways.
This
angle for toe out
on turns is designed to permit both front wheels to
turn
on a common center by having the ends of the
steering
knuckle
arms closer
together
than the king
pins.
To
avoid possible damage to the universal joints
on the front axles of 4-wheel drive vehicles, it is advisable to check the turning angle.
Wearing
away
of the upset
edge
on the spindle housing bolt which
10607
FIG.
0-6—TURNING
ANGLE
STOP
SCREW
1—Stop
Screw
contacts the
stop
screw
will
increase the turning
angle to the point where the universal joints may
be damaged.
The
Jeep Universal Series vehicles should have a
turning
angle of not more than 27^° both left and
right.
To adjust the
stop
screw, it is necessary to
loosen
the locknut holding the
stop
screw. When
the adjustment has been made, tighten the locknut
on the screw to prevent any movement. Refer to
Fig.
O 6.
The
left steering knuckle arm controls the relation
ship of the front wheels on a left
turn
and the right
arm
controls the relation on a right
turn.
0-12. Steering
Knuckle
Arm
Should
a steering knuckle arm
become
bent, the
knuckle
housing must be replaced. It is not safe to
straighten the knuckle arm.
0-13.
Front
Wheel
Shimmy
Wheel
shimmy may be caused by various condi
tions in the wheels, axle or steering system, or a
combination of
these
conditions. Outlined below
will
be found the usual corrections of this fault:
a.
Equalize
tire pressures and see that they are
according
to specifications.
b.
Check
the wheel bearings for
looseness.
Be sure
that the inner wheel bearing race is not too
loose
on the spindle.
c.
Remove both steering knuckles and carefully inspect the upper and lower king pin bearings.
Inspect
the bearing cups for evidence of brinelling,
pitting, or fretting. Any bearings that show the slightest imperfection must be
replaced.
Reassemble
and
lubricate the front axle and steering linkage,
installing
new steering knuckle oil seals if present
seals show any wear.
d.
With
full
weight on the front wheels and one
man
working the steering play with the steering
wheel, a second man should closely observe the steering bell
crank
for any rocking motion and the
double tie rod socket for any rocking motion or
looseness
at both points. Replace the complete bell
crank
assembly if it has even the slightest rocking motion. The same applies to the double tie rod
socket.
e.
Check
wheel run-out.
This
check should include
radial
run-out and wheel
looseness
on the hub.
f- Test wheel balance—check for blowout patches,
uniform
tire tread, vulcanized tires, mud on inside
of wheels, and tires creeping on the
rims.
g.
Try
switching front wheels and tires to the
rear,
criss-crossing
them in this operation.
h.
Check
for front
spring
sag. Also check for broken
spring
leaves, broken center
spring
bolt,
loose
spring
clips
(or tight clips), over-lubrication of spring leaves, spring shackle bracket
loose
on frame, and
loose
rear
spring shackle. Be sure that the shock
absorbers
are operating properly to eliminate bobbing of the front end.
i.
Check
brakes to make sure that one
does
not
drag.
j.
Check
the steering assembly and steering con necting rod.
This
includes the up-and-down-play
of the steering worm shaft, end play of the cross 317

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
P The
standard parking brakes (Fig. P-3) consist of
cable-controlled linkage for applying the rear wheel
brake
shoes
mechanically. A single cable from the
parking
brake control lever is connected, by means of an equalizer, to cables leading to individual rear
brakes.
A lever attached to the secondary
shoe,
with a link acting against the
primary
shoe,
expands the
shoes
into
contact with the drums.
P-4.
Transmission Brake
The
transmission brake is mechanically operated
by a hand lever through a cable and conduit and is mounted at the rear output bearing housing on the
transfer case. The transmission brake and its
linkage are shown in Fig. P-4.
P-5.
Brake Maintenance
No brake can be
expected
to work well when grease
or oil is allowed to leak
into
the drum from the rear axle. Little braking friction can be obtained
between
brakes and drums when the surface is
covered with grease and oil. For this reason, take
care
not to over-lubricate wheel bearings, forcing
lubricant
past seals. Also, check condition of seals
if
leak is suspected or whenever brake drums
are
pulled.
Whenever
wheels
are removed, it is advisable to
wash the drums with a suitable solvent so that all
grease and dirt are removed. Linings with any
evidence of grease or oil on them should be replaced.
The
hydraulic system should be kept free of dirt
and
moisture.
Use only SAE standard J-1703 Hydraulic
Brake
Fluid.
Caution:
Keep mineral oils, gasoline, or kerosene
out of the system as
they
cause rubber cups to
soften,
swell, and distort, resulting in failure.
P-6.
Brake
Service
To
service the brakes,
follow
the procedure
below:
a.
Check the fluid level in the brake master cylin
der.
See Lubrication Section, Par. B-40.
b. Check brake pedal adjustment. See Par. P-9.
c. Check brake pedal travel. If the pedal travels more than halfway to the floor, the brake system
must be checked and the self adjusting star wheel mechanisms checked for binding, also the brake
linings should be inspected as
they
may be badly
worn.
How much lining is
left
can only be deter mined by visually inspecting the linings. See Par.
P-l6 for relining brakes.
d.
If the brakes pull to one side after adjustment, check tire pressures. All tires must be inflated to recommended pressures to ensure even braking. If
the condition persists, examine the brake linings
for foreign material and clean as necessary. If clean
ing
does
not correct the condition the linings should be replaced. If the side pull persists, check front
wheel alignment and balance.
e. Check the brake system for leaks by applying a steady pressure on the brake pedal. A leak in the
system
will
allow the pedal to "fall away". If the pedal "falls away" check for a leaking wheel cylin
der.
Remove
wheels
and drums and carefully check
each cylinder. Also examine all lines and fittings.
Rebuild
or replace all wheel cylinders (Par. P-21)
if
one is
defective
as
they
are all probably in poor condition. If the leak has allowed brake fluid to get
on the linings, the linings
will
have to be replaced.
f. A
"spongy"
brake pedal indicates the pressure of air in the hydraulic system.
This
condition must
be corrected by bleeding the brakes. See Par. P-7.
g. Should the brakes
become
locked so that the vehicle cannot be moved, the brakes may be re
leased by opening the bleeder screw on any one of the wheel cylinders. Before the vehicle is driven, correct the cause of the condition. The cause may
3
14 15 16 17 18
4
10796
1—
Cable
and Conduit
2—
Hand
Brake
Clip
3—
Hand
Brake
Bracket
4—
Hand
Brake
Handle Assembly 5—
Rear
Cap
6—
Drive
Gear
Bushing
7—
Driven
Gear
8—
Driven
Gear
Sleeve
FIG.
P-4—TRANSMISSION
BRAKE
9—Backing
Plate
10— Shoe and
Lining
11—
Lever
End Return Spring
12—
Brake
Drum
13— Bolt 14—
Rear
Companion Flange
15—
Washer
16— Nut 17— Propeller Shaft Flange Yoke
18—
Rear
Propeller Shaft
19—
Adjusting
End Spring
20—
Adjusting
Screw Bracket
21—
Operating
Lever
22—
Clevis
23—
Retracting
Spring
Clip
24—
Retracting
Spring
Link
325

p
BRAKES
P-25.
SERVICE
SYMPTOMS
Brakes Drag
Brake
Shoes
Improperly Adjusted
Piston Cups Enlarged . . •.
«•
Mineral
Oil or Improper Brake
Fluid
in System. . .
Improper
Pedal Adjustment
Clogged Master Cylinder By-Pass Port...
One
Brake Drags
Brake
Shoe
Adjustment Incorrect
v Brake
Hose
Clogged.
Return
Spring Broken
Wheel Cylinder Piston
01
Cups
Defective.........
Loose or Damaged Wheel Bearings
Brake Grabs
—
Vehicle Pulls
to One
Side
Grease
or Brake
Fluid
on
Lining................
Dirt
Between
Lining
and Drum
Drum
Scored or Rough
Loose Wheel Bearings. .
Axle Spring Clips Loose
Brake
Backing Plate Loose
Brake
Lining
..
Brake
Shoe
Reversed
Tires
Under-Inflated -
Tires
Worn Unequally
Glazed
or Worn
Lining
Restricted Brake
Line
Excessive Pedal Travel
Normal
Lining
Wear
Lining
Worn Out ... .
Leak
in Brake
Line.
Scored Brake Drums
Incorrect
Brake
Lining.
Air
in Hydraulic System
Spongy Brake Pedal
Air
in
Lines.
Brake
Shoe
Adjustment Incorrect
Insufficient Brake
Fluid
Excessive Pedal Pressure
Grease
or Brake
Fluid
in
Lining
Shoes
Improperly Adjusted
Warped
Brake
Shoes
Distorted Brake Drums
Glazed
or Worn
Lining
Restricted Brake
Line
Faulty
Brake Cylinder Insufficient Brake
Fluid.
Squeaky Brakes
Shoes
Warped or Drums Distorted
Lining
Loose.....
Dirt
Imbedded in
Lining
Improper
Adjustment.
Oil
or Grease on
Lining
Glazed
or Worn
Lining.
Drum
Scored
DIAGNOSIS
PROBABLE
REMEDY
Adjust
Flush
all
lines
with Alcohol. Install new cups in wheel and Master Cylinders
Adjust
Master Cylinder Eye Bolt
Clean
Master Cylinder
Adjust
Replace Replace
Replace
Adjust
or Replace
Replace
Lining
Clean
with Wire Brush
Turn
Drum and Replace
Lining
Adjust
Tighten Tighten
Different Kinds on Opposite Wheels
Forward
and
Rear
Shoes
misinstalled
Inflate
Replace or Rotate Replace Linings
Locate
and Repair
Adjust
Replace
Locate
and Repair Replace or Regrind Replace
Fill
Master
Cylinder
— Bleed Lines
Bleed Lines
Adjust
Fill
Master Cylinder
Replace
Lining
Major
Adjustment
Replace
Replace or Regrind Replace Linings * .
Locate
and Repair
Repair
or Replace
Fill
Master Cylinder Replace
Replace
Wire
Brush or Replace
Adjust
Replace Linings Replace Linings
Turn
Drum and Replace Linings 334

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
FIG.
Q-5—REAR
WHEEL
ATTACHING
PARTS —
FLANGED
AXLE
1—
Brake
Backing Plate
2—
Retainer
Ring
3—
Unit-Bearing
4—
Oil
Seal
5—
Retainer
Plate 6—
Brake
Drum
7—
Cup
Plug
8—
Flanged
Axle Shaft
14284
Q-4. Checking
Front
Wheel Bearings
Raise
the front end of the vehicle with a
jack
so that the tires clear the floor.
Grip
the tire and
test
sidewise shake of the wheel.
If
bearings are correctly adjusted, shake of the
wheel
will
be just perceptible and wheel
will
turn
freely with no drag.
If
bearing adjustment is too tight, the rollers may
break
or
become
overheated. Loose bearings may cause
excessive
wear and noise.
If
this
test
indicates bearing adjustment is neces
sary,
follow
the procedure given in Par. Q-5. Loose
bearings
will
cause sidewise shake that is evident
around
the entire circumference of the wheel. A shake that is evident only when gripping the
wheels
in
a plane parallel to the ground, but not evident
around
the entire circumference, probably indicates
looseness
in the steering linkage.
Q-5.
Front Wheel Bearing Adjustment
With
the vehicle on the
jack,
the following proce
dure
should be followed to adjust the front wheel
bearings on four wheel-drive vehicles.
a. Remove the hub cap, snap
ring,
capscrews, and
washers that attach the driving
flange
to the hub.
b.
Using the
Front
Axle Shaft Drive Flange Puller
W-163,
pull
the driving flange.
c. Bend the lip of the nut lock washer so that the
locknut
and lock washer may be removed.
d.
Rotate the wheel and tighten the adjustment nut until the wheel binds.
Note:
Front
tire and wheel must be rotated by
hand
as the adjusting nut is
tightened
to ensure positive seating of the bearing.
Then
back off the adjusting nut about one-sixth
turn
making sure that wheel rotates freely without
sidewise shake.
e. Replace the lock washers and locknut. Bend
over the lock washer lip.
f.
Check
the adjustment (Par. Q-4). Reassemble the driving
flange
and hub cap. Make certain the
gasket is properly installed
between
the hub and
the flange.
•
Model DJ-5, DJ-6
On
two-wheel drive vehicles, remove the hub cap
and
the wheel retaining nut cotter pin. Rotate the
wheel and tighten the wheel retaining nut until the wheel binds.
Then
back off nut about one-sixth
turn
or more if necessary making sure wheel ro
tates
freely without sidewise shake. Replace the cotter pin and hub cap.
Q-6.
Rear
Wheel Bearing Adjustment —
Flanged
Axle Shaft
Vehicles
equipped with the
flange
type
rear
axle
shaft require no wheel bearing adjustment. The flanged axle shaft is equipped with a single row,
pre-adjusted,
tapered roller unit-bearing capable of
accepting thrust in either direction. The unit-
bearing
adjustment is built in at the factory mak
ing shimming or bearing adjustment unnecessary.
Refer
to Fig. Q-6.
Q-7.
Checking
Rear
Wheel Bearings —
Tapered
Axle
Raise
wheel on which adjustment is to be made
by placing a
jack
under the axle housing.
With
hands,
test
sidewise shake and in and out play
of the wheel. If bearings are correctly adjusted,
shake of wheel
will
be just perceptible and the 337

Q
WHEELS
FIG.
Q-6—REAR
WHEEL,
FLANGED
AXLE
AND
BEARING
ASSY.
1—
Retainer
Plate
2— Oil
Seal
3—
Unit
Bearing
4—
Retaining
Ring
5—
Axle
Shaft
wheel
will
turn
freely with no drag. If adjustment
is necessary, follow the procedure given in Par. Q-8.
Q-8.
Rear Wheel Bearing Adjustment
—
Tapered Axle
The
bearing adjusting shims are placed
between
the brake backing plate and axle flange as shown
in
Fig. Q-7.
With
wheel raised on
jack,
the following procedure
should be used to make the
rear
wheel bearing
adjustment.
a.
Remove the hub cap with hub cap puller, the
cotter pin, axle shaft nut, and washer. Remove the
wheel hub and drum with a wheel puller.
b.
Disconnect hydraulic brake line at wheel
cylinder.
c.
Remove the
bolts
holding the brake dust shield, grease and bearing retainer, and the brake backing
plate.
d.
Remove or install shims to adjust the bearings
to provide .001" to .006" [0,025 a 0,152 mm.]
end float of the axle shaft.
Note:
Before reassembly of the wheel make certain
the backing plate nuts are tight and torqued at 25 to 35 lb-ft [3,4 a 4,8 kg-m.].
e. Reassemble the wheel, adjust brakes, and check
the bearing adjustment (Par. Q-7).
0-9.
REAR WHEEL MOUNTING
—
TAPERED AXLE
Proper
axle shaft key installation is accomplished by placing the hub and drum on the axle shaft
taper and then inserting the axle shaft key in the
FIG.
Q-7—REAR
WHEEL
AND HUB
BEARING
—
TAPERED
AXLE
SHAFT
1—-Adjusting
Shims
2—Inner
Seal
3—Outer
Seal
keyway.
Never install the key in the keyway before
placing
the hub and drum assembly on the axle
shaft. Be sure that the axle shaft nut is torqued
to a minimum of 150 lb-ft. [20,7 kg-m.].
O-10.
BRAKE
DRUM
SERVICE
On
rear
wheels, the hub fits inside the brake drum
(Fig.
Q-3). On front wheels, the hub is attached
to the outside of the brake drum (Fig. Q-l). The
brake
drums are attached to the wheel hubs by
five serrated bolts. These
bolts
are also used for
mounting the wheels on the hub. To remove a
brake
drum,
press or drive out the serrated
bolts
and
remove the drum from the hub. When placing
the drum on the hub, make sure that the contacting
surfaces are clean and flat.
Line
up the
holes
in
the drum with
those
in the hub and put the drum
over the shoulder on the hub. Insert five new
serrated
bolts
through the drum and hub and drive
the
bolts
into place solidly. Place a round head of the bolt in a vise. Next, place the hub and drum
assembly over it so that the bolt head rests on it.
Then
swage
the bolt into the countersunk section of the hub or drum with a punch. The runout of
the drum face should be within .030" [0,76 mm.]
total indicator reading. If the runout is found to be greater than .030" it
will
be necessary to reset
the
bolts
to correct the condition.
0-11.
TIRE SERVICE
Refer
to Fig. Q-8.
One
of the most important factors of safe vehicle
operation is systematic and correct tire mainte nance.
Tires
must sustain the weight of a loaded vehicle, withstand more than ordinary rough serv- 338

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
Q
ice, provide maximum safety over all
types
of
terrain,
and furnish the medium on which the
vehicle can be maneuvered with ease. Although
there are other
elements
of tire service, inflation maintenance is the most important and in many
instances the most neglected. The tire pressure should be maintained for safe operation. An under- inflated tire is dangerous as too much flexing can
cause breakage of the casing. Overinflation in time
may
cause a blowout.
Upon
careful inspection of tires, it may be found
that improper wheel alignment, balance, grabbing
brakes,
poor driving habits, fast cornering or other
conditions are the cause of wear. Such conditions
should be corrected.
a.
UNDERINFLATION
Underinflation
distorts the normal contour of the
tire
body and the tire
bulges
or "bellies out" with
an
extreme flexing action.
This
wears the tread at the
edges
more than the center and generates
excessive internal heat, weakening the cords and
resulting
in bruises, broken cords or ply separation.
Underinflation
also leads to rim bruises as in sufficient resistance is provided to prevent the tire
from
being jammed against the rim and crushed
or
cut when the tire strikes a
curb,
rock, or rut.
b.
OVERINFLATION
When
a tire is
overinf
lated,
increased tension caused by excessive pressure prevents proper deflection of
the sidewalls.
This
results in wear in the center of the tread and the tire also
loses
its ability to absorb
road
shocks. Under this increased
strain,
cords in the tread area eventually snap under impact, causing a casing break.
c.
MISALIGNMENT
WEAR
Excessive
wheel camber causes the tires to run at an angle to the road when camber is incorrect
it
will
cause excessive wear on one side of the
tire
tread.
Front
wheels should be straight ahead or toe-in slightly. When there is excessive toe-in or
toe-out,
tires
will
revolve with a side motion and scrape
the tread rubber off.
Front
tires
will
show wear on the outside with too great a toe-in condition
and
on the inside with a
toe-out
condition.
d.
BALANCE
Cupping
and bald spotting of tires is associated
with
wear on a vehicle driven mostly at high-way
speeds
without the recommended tire rotation and
with
unbalance conditions.
Q-12.
Tire
Care
Note;
For satisfactory 4-wheel drive operation, a
4-wheel drive vehicle
MUST
be equipped with the same size tires of equal circumference on all
four wheels. The tires must then be inflated to
proper
factory recommended pressures at all times.
Tire
pressure, tire rotation, wheel balance, and wheel alignment are the four vital factors that in
fluence the
extent
of tire life and the
ease
and safety of vehicle control.
Four
of the most common
tire
troubles are:
a.
Excessive wear around the outer
edges
resulting
from
underinflation.
b.
Excessive wear in the center of the tread re
sulting from overinflation.
c.
Tire
tread worn on one side indicating wheels
need realigning.
d.
Cuplike
depressions on one side of the tread
indicating
wheels need balancing.
If
the vehicle normally carries a
full
load, two to
four psi. [0,14 a 0,28 kg-m2] can be added to the
recommended air pressures. But, remember that adding air with a light load means a harsher ride,
doesn't
help tires, and wears out shock absorbers. Rotate the tires as shown in Fig. Q-9 for correct
rotation system.
Q-13.
Tire
Removal
and
Installation
To
remove a tire from a drop center rim, first
WEAR
AT SHOULDERS
WEAR
AT CENTER
WEAR
ON ONE
SIDE
FEATHERED
EDGE
BALD
SPOTS
/1TTDN
i
UNDER
INFLATION
OVER
INFLATION
EXCESSIVE
CAMBER
INCORRECT
TOE
WHEEL
UNBALANCED
liF
11
ADJUST
PRESSURE TO
SPECIFICATIONS
WHEN
TIRES ARE
COOL
ADJUST
CAMBER
TO
SPECIFICATIONS
ADJUST
FOR
TOE-IN
DYNAMIC
OR
STATIC
BALANCE
WHEELS
FIG.
Q-8—TIRE
WEAR
PATTERN
339

Q
WHEELS
11463
FIG.
Q-9—TIRE
ROTATION
1—
Right
Front
Tire
2—
Right
Rear
Tire
3—
Spare
Tire
4—
-Left
Rear
Tire
5—
Left
Front
Tire
deflate completely and then force the tire away
from
the rim throughout the entire circumference
until
the bead falls into the center of the wheel
rim.
If the vehicle is equipped with tires that use
an
inner tube, carefully remove the inner tube.
With
the inner tube removed, or on tubeless tires, a tire
removing tool should be used to remove the tire
from
the rim.
Installation
of the tire is made in the same manner
by first dropping one side of the tire into the center
of the rim and with a tire tool raise the bead over
the wheel
rim.
The inner tube can now be installed
on vehicles so equipped.
When
mounting the wheel, alternately tighten op
posite stud nuts. After the nuts have been tightened
with
the wheel jacked up, lower the
jack
so wheel rests on the floor and retighten nuts. Torque nuts
to 60-75 lb.-ft. [8,3 a 10,4 kg-m.].
Note:
New "wide" tires have been given new sizes
by tire manufacturers. They use a letter as a key
unit
in the name size for the new wide treads.
The
single letter in front of the "70" indicates load rating, or the weight a tire can support safely
when inflated to 32 psi. The number 70 is used to show the
7-to-10
(70 percent) ratio of tire section height to width. The last two-digit number of the new sizes— 15 —
is
the rim diameter.
Radial
ply
tire sizes all contain the letter
"R"
to designate
radial
ply construction.
15-inch
Diameter
New Old
E70-15
7.35-15
F70-15
.7.75-15
G70-15
8.15-15
H70-15
8.45-15
J70-15
.8.85-15
K70-15
. .... .9.00-15
L70-15
9.15-15
You
should explain to customers
these
new tire
designations. Such knowledge
will
act as a re
minder
never to mix
radial
ply, wide treads or
conventional tires on one axle.
0-14.
WHEEL
AND
TIRE
SPECIFICATIONS
'Jeep'
Universal
V6
Engine
CJ-5,
CJ-6,
CJ-5A,
CJ-6A
'Jeep*
Universal
F4
Engine
CJ-3B,
CJ-5,
CJ-6
DJ-5,
DJ-6
WHEELS:
Rim
Size 15 x
6.00
16 x 4.50
15 x 5.50
K
E
K
Attachment
Type
Stud
Stud Stud
Circle
Dia 5.50 5.50 5.50
5 5
4
Size
H-20
H-20
H-20
Rear
Axle Shaft End Float .001*-.006"
.001"-.006" .001 *-.006"
[0 ,025 a 0,152 mm.)
[0,025 a 0,152 mm.] [0,025 a 0,152 mm.]
TIRES:
Size.
7.35-15
6.00-16
6.85-15
Ply
Rating 4
4 2
Revolutions per Mile @ 30 mph.. . 781 730 803
Inflation
Pressure
Front
20
psi
[1,406 kg-cm2]
20 psi [1,406 kg-cm2] 24 [1,687 kg-cm*]
Rear
24
psi
[1,687 kg-cm*]
20 psi [1,406 kg-cm2] 24 [1,687 kg-cm*] 340