1953 JEEP CJ lock

K

TRANSFER
CASE
the brake drum and companion
flange
by remov­
ing bolts, lockwashers, and nuts.

b.
Remove the oil seal with Tool W-251, as shown

in
Fig. K-7.

c.
Remove
speedometer
driven gear assembly.

d.
Remove the cap screws attaching the cap and
brake
backing plate to the case.
Take
precautions
not to
lose
or damage bearing adjusting shims placed
between
the cap and the transfer case
housing.
e. Separate the
rear
cap and brake backing plate
assembly. See Section P for brake service pro­
cedures.
f. Remove
speedometer
driving gear.

K-6.
Transfer
Case
Reassembly
•
Refer to Fig. K-1, K-2.

Reassembly
of the transfer case is reversal of the

foregoing
procedure of disassembly. The output shaft snap ring may
best
be installed with Tool
FIG.
K-11—OUTPUT
SHAFT
SNAP

RING
INSTALLER
1—
Snap
Ring

2—
Snap
Ring
Installer Tool W-131
FIG.
K-12—OUTPUT
SHAFT
OIL
SEAL
DRIVER

1—
Driver
Tool W-143

2—
Seal
W-131,
output shaft snap ring installing thimble

and
driver,
shown in
Fig.
K-ll.
Use a
piece
of tub­
ing for installing the bearing
cone
and roller as­ semblies on the output shaft to prevent damage
to the assemblies.

Early
production transfer cases were equipped with
a
lVs" [2,86 cm.] diameter intermediate shaft

and
caged
needle
bearings. When installing the intermediate gear in early production transfer cases,

insert
the bearings in the gear, support the front

thrust
washer with Pilot Pin Tool W-192,
Fig.
K-10,
position the gears and
rear
thrust washer, and
insert
the shaft from the
rear
of the case.

Late
production transfer cases were equipped with
a
1
Vi"
[3,18 cm.] diameter intermediate shaft,

and
bearings consisting of individual rollers and
spacers.
A dummy shaft is required to install the
intermediate shaft. The dummy shaft should be slightly smaller in diameter than the intermediate
shaft and a little shorter than the width of the
intermediate gear. To install the intermediate gear,

first
load the bearing rollers and spacers in the gear using the dummy shaft.
Then
supporting the
front thrust washer with the fingers, position the gears and
rear
thrust washer and insert the shaft

from
the
rear
of the case, driving out the dummy
shaft.

Should
it be necessary to replace the
speedometer

driven
pinion bushing installation may be
best

made with bushing installer Tool W-133, shown
in
Fig. K-13. When the
rear
bearing cap assembly
is installed, check the end
movement
of the main-
shaft which determines the adjustment of the
tapered roller bearings. For correct bearing adjust-
|
11S4S

FIG.
K-13—SPEEDOMETER
PINION
BUSHING
DRIVER
1—Tool W-133
272

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

K
ment, the shaft should have .004" to .008"
[0,102

a
0,203
mm.] end play. Adjustment is made by
selective
shim installation
between
the cap and the
case. Shims .003", .010" and .031" [0,076,
0,254,

0,787
mm.] in thickness are available for this ad­
justment. Do not install the rear cap oil seal until
the bearings are correctly adjusted. Both the front
and
rear oil seals may be installed with oil seal

driver
Tool W-143, shown in Fig. K-12.

When
installing the end yokes on the output shafts,
inspect for the presence of
felt
seals in each oil
seal guard. (The oil seal guard is a part of each
yoke assembly.) Felt seals should be installed in the oil seal guards if
they
are not present. When
installing the shift
rail
oil seals in the front bear­
ing cap, it is necessary to protect the seals against
damage when passing over the shift
rail
notches.
Protect them with the thimble, and install them with the driver, Tool W-130, shown in Fig. K-9.

K-7.
Transfer Case Installation

The
installation of the assembly in the vehicle is
the reverse of the removal operation covered in
Par.
K-2.

If
the transmission was removed from the vehicle,
lubricate the pilot bearing and also lubricate the
transmission and transfer case as outlined in the

"Lubrication
Section". Be sure that the clutch pedal has %"
[19,05
mm.] free travel as outlined

in
the
"Clutch
Section".

K-8.
Transfer Case Linkage Adjustment

Adjust
the link to provide
xh"
[12,7 mm.] clear­
ance
between
the floor pan and the shift lever
bend when operating in four wheel drive low
position. Refer to Fig. K-4.

K-3.
TRENSFER
CESE
SERVICE
DIAGNOSIS

SYMPTOMS PROBABLE REMEDY

Slips
Out of
Gear (High-Low)
Shifting
Lock
Spring Weak Replace Spring

Bearing
Broken or Worn Replace
Shifting
Fork
Bent Replace

Slips
Out of
Front Wheel Drive
Shifting
Lock
Spring Weak. Replace

Bearing
Worn or Broken Replace

End
Play in Shaft. . . ..... Adjust Shifting
Fork
Bent.. Replace

Hard Shifting
Lack
of
Lubricant
Drain
and
Refill

Shift
Lever
Stuck on Shaft Remove, Clean and Lubricate
Shifting
Lock
Ball
Scored Replace
Ball

Shifting
Fork
Bent Replace
Fork

Low
Tire
Pressure Inflate

Grease Leak
at
Front
or
Rear Drive
Grease
Leak
at Covers. Install New Gaskets

Grease
Leak
between
Transmission and Transfer Cases Install New Gaskets

Grease
Leak
at Output Shaft Install New Oil Seal

K-10.
TRANSFER
CESE
SPECIFICATIONS

Transfer
Case:
All
Models

Spicer

18

On
Floor

Gear
Ratio: 1.00 to 1
2.46 to 1 273

M
FRONT
AXLE
1— Nut
2—
Lock
Washer

3—
Bearing
Lock
Washer
4—
Wheel
Bearing Cup 5—
Cone
and Rollers
6—
Oil
Seal 7— Spindle
8— Spindle Bushing
9—
Filler
Plug
10—
Right
Knuckle and Arm
11— Shims
12— Pivot Pin
13—
Lock
Washer
14—
Cap
Screw
15— Nut
16—
Washer

17—
Universal
Joint Yoke
18—
Oil
Seal
19—
Oil
Slinger
FIG.
M-2—FRONT
AXLE

20—
Cone
and Rollers
21—
Bearing
Cup
22—
Right
Axle Shaft with Universal Joint
23—
Knuckle
Oil Seal Retainer
24— Housing Breather 25—
Front
Axle Housing
26—
Axle
Shaft with Universal Joint
27—
Oil
Seal
28—
Axle
Shaft Guide
29—
Shim
Pack
30—
Bearing
Cup
31—
Cone
and Rollers
32—
Ring
Gear
and Pinion
33—
Thrust
Washer

34—
Thrust
Washer

35—
Differential
Gears
36— Housing Cover Gasket
37— Housing Cover
38—
Fill
Plug 39—
Screw
and
Lock
Washer
40—
Bearing
Cup
41—
Cone
and Rollers
42— Shims
43—
Lock
Pin
44—
Pinion
Shaft
45—
Differential
Case
47— Bolts
48— Nut
49—
Oil
Seal and Backing Ring
50—
Thrust
Washer
51— Snap Ring
52— Stop Bolt
53— Nut 54—
Bearing
Cup
55—
Cone
and Rollers
56—
Gasket

checked, making sure it is clean and open.

The
front wheel bearings should be checked every
12,000
miles. Refer to Section Q. Front wheel toe-

in
is adjustable by lengthening or shortening the
tie rod. However, standard caster and camber of
the front
wheels
are built
into
the axle. Wheel
caster can be adjusted by placing tapered shim
plates or
wedges
between
the springs and spring

seats
welded to the axle housing. Steering
geometry

and
front wheel adjustments are discussed in Sec­ tion O.

The
axle housing should be checked periodically
for weld cracks and/or other damage that may cause misalignment of the front
wheels
or
loss

of lubricant. The spring clips (U-bolts) should be
inspected and torqued every
12,000
miles. Torque (spring clip) nuts 45 to 50 lb-ft. [6,2 a 6,9 kg-m.].

M-4. FRONT
AXLE
REMOVAL
a.
Raise front end of vehicle
arid
safely support the frame by placing stands under the frame at
the rear of the front spring rear hangers.
b. Place
jack
under front axle housing and relieve
axle
weight
from the springs.
c. Disconnect shock absorbers from spring clip plates.
FIG.
M-3—HUB
CAP
PULLER

d.
Disconnect steering link from tie rod socket-
joint assembly.
e. Disconnect hydraulic brake
hoses
from front

brake
lines. Disconnect
hoses
from frame brackets. 278

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

m f. Disconnect propeller shaft from the differential
companion flange.

g.
Disconnect both front springs from front spring hangers.

h.
Remove spring clip and spring clip plates secur­
ing axle to front springs.

i.
Remove front
wheels
from axle assembly.

j.
Lower
jack
slightly and
pull
axle forward from
under
vehicle.
M-5.
FRONT AXLE SHAFT REMOVAL

Refer
to Fig. M-2.

The
following procedure applies to either right or
left
front axle shaft.

Note:
Axle shafts can be removed without remov­
ing the axle housing from the vehicle. Use the fol­
lowing procedure.
First
raise and support front end
of vehicle, and remove front wheels.

a.
Remove drive
flange
snap
ring.
b-
Remove the hub cap with a puller as shown in

Fig.
M-3.

c.
Remove the axle shaft driving
flange
bolts.

d.
Apply the
foot
brakes and remove the axle shaft
flange
with puller W-163 as illustrated in

Fig.
M-4.
FIG.
M-4—AXLE
SHAFT
DRIVE
FLANGE
PULLER

1—Too!
W-163
e.
Release the locking lip on the lockwasher and
remove the outer nut, lockwasher, adjusting nut

and
bearing lockwasher. Use wrench W-144, Fig.

M-5,
for removal of the nut.
f- Remove the wheel hub and drum assembly

with
the bearings. Be careful not to damage the

oil
seal.
FIG.
M-5—WHEEL
BEARING
NUT
WRENCH

1—Tool
W-144
g.
Remove the hydraulic brake
tube
and the

brake
backing plate screws.

h.
Remove the spindle.
i.
Remove the axle shaft and universal joint as­
sembly.
M-6.
Removing
and
Overhauling Differential

Adjustment
and overhaul of the front axle differen­
tial
assembly is the same as that of a
full
floating

type
rear
axle. Information covering dismantling

and
assembling of this
type
differential is contained
in
Section N.

NOTE:
All service replacement axle assemblies

are
shipped from the factory without lubricant in
the differential.
Lubricant
must be added to the
differential
before
the axles are installed in vehicles.

Use
the grade and quantity of lubricant specified
in
the lubrication section.

After
the axle has
been
installed in the vehicle,

check
to be sure the lubricant level in the dffer-

ential
is level with the
fill
plug opening.
M-7.
AXLE SHAFT UNIVERSAL JOINT SERVICE

Refer
to Fig. M-6 and M-7.

After
the axle shaft and universal joint assembly have
been
removed, the
Cardan
cross universal

joint
can be disassembled and inspected as follows:

a.
Remove the snap rings from the bearing cup assemblies.

b.
Press on the end of one bearing cup assembly

until
the
opposite
bearing is pushed from the yoke

arm.
Turn
the yoke over and press the first bear­ ing back out of that
arm
by pressing on the
exposed

end of the
journal
shaft. To avoid damaging the 279

M

FRONT
AXLE
FIG.
M-6—CARDAN

CROSS
UNIVERSAL
JOINT

1—Axle
Shaft Yoke
Half

2-—Bearing Cup
3— Snap Ring 4— Axle Shaft Yoke
Half
5— Roller Bearing
6— Bearing Cup 7— Bearing Cross Journal
10527

FIG.
M-7—CARDAN
CROSS
UNIVERSAL
JOINT
1— Outer Axle Shaft Snap Ring
2— Outer Shaft
3— Bearing Retainer Snap Ring
4— Bearing Rollers 5— Bearing Retainers
6— Universal Joint Journal Assembly 7—
Inner
Shaft bearing, use a
soft
drift with a
flat
about

[0,8 mm.] smaller in
diameter
than the
hole
in the

yoke
arm to drive out the bearing.
c.
Repeat
the
above
step
for the
other
two
bearings.
Then
lift
out the
bearing
cross
journal by
sliding

it to one
side.

d. Wash all parts in
cleaning
solvent
and
inspect

the parts
after
cleaning.
Replace any parts
that
indicate
extensive
wear.
e. Pack the
bearing
cones
one-third
full of lubri­
cant
and install the rollers.
f. Insert the
bearings
into
the end
yoke
arm and

seat
them
firmly
against
the
bearing
shoulders.

g.
Holding
the
bearings
in a vertical
position
to
prevent
the
needles
from
dropping
out,
reassemble

the joint in the
reverse
order of the
disassembly.
FIG.
M-8—STEERING KNUCKLE AND WHEEL BEARINGS
1— Bearing Adjusting Nut
2— Lockwasher
3— Lockwasher
4— Bearing Cone and Rollers 5— Bearing Cup
6— Spindle 7— Bushing
8—
Filler
Plug 9—Left Knuckle and Arm
10— Shims
11— Upper Bearing Cap 12— Lockwasher
13—Bolt
14—
Oil
Seal and Backing Ring
15—
Thrust
Washer
16— Axle Pilot 17—
Oil
Seal
18— Bearing Cup
19— Bearing Cone and Rollers
20—
Oil
Seal
21— Retainer
22— Bolt
23—
Lower
Bearing Cap
24—
Lock
Strap
25— Bolt 280

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

M
If
the joint binds when assembled, tap the yoke
lightly to relieve any pressure on the bearings at the end of the
journal.

M-8-
Steering
Knuckle
Service

The
steering knuckle pins pivot on tapered roller
bearings. Replacement of
these
bearings requires

removal
of the hub and brake drum assembly,
wheel bearings, axle shaft, spindle, steering tie rod,

and
steering knuckle. Disassemble the steering
knuckle
as follows:
Remove the
eight
screws which hold the oil seal

retainer
in place. Remove the four screws holding
the lower pivot pin bearing cap. Remove the four screws holding the upper bearing cap in place. Re­
move
the bearing cap. The steering knuckle can
now be removed from the axle. Wash all parts in cleaning solvent. Replace any damaged or worn

parts.
Inspect the bearing and races for scores,
cracks,
or chips. Should the bearing cups be damaged,
they
may be removed and installed with

Special
Driver
W-138, as shown in Fig. M-9.
M-9.
Reassemble
and
Bearing Preload

Reverse
the procedure of Par. M-8 to reassemble
the unit. When reinstalling the steering knuckle, sufficient shims must be installed under the top

bearing
cap to obtain correct preload on the bear­
ing.
Shims are available in
these
thicknesses: .003"
[0,076
mm.] .010"
[0,254
mm.] 005"
[0,127
mm.] .030"
[0,762
mm.]

Install
one each of the
above
shims at the top only.
Install
the bearing caps, lockwashers, and screws,

and
tighten securely.
Check
the preload on the bearings by hooking a

spring
scale, Tool C-690, in the
hole
in the knuckle

arm
for the tie rod socket.
Take
the scale reading when the knuckle has just started its
sweep.

The
kingpin bearing preload should be 12 to 16 lb. [5,43 a 7,24 kg.] with the oil seal removed. Remove

or
add shims to obtain a preload within
these
limits.
FIG.
M-9—SPINDLE
PIN
BEARING
CUP
DRIVER

1—Tool
W-138
FIG.
M-10—TURNING
ANGLE
STOP
SCREW

1—Stop
Screw
M-10.
Replacing Steering
Knuckle
Oil Seal
Remove the old steering knuckle oil seal by remov­ ing the
eight
screws which hold it in place.
Earlier

production vehicles are equipped with seals con­ sisting of two oil seal halves.
Later
production vehicles are equipped with oil seal assemblies con­
sisting of a split oil seal and backing ring assembly,

an
oil seal felt, and two seal retainer plate halves.

Examine
the spherical surface of the axle for scores or scratches which could damage the seal.
Smooth any roughness with emery cloth. Before installing the oil seal felt, make a diagonal
cut across the top side of the
felt
so that it may be
slipped over the axle.
Install
the oil seal assembly

in
the
sequence
given above, making sure the

backing
ring (of the oil seal and backing ring as­
sembly) is toward the wheel.

After
driving in wet, freezing weather swing the
front
wheels
from right to
left
to remove moisture

adhering
to the oil seal and the spherical surface of
the axle housing.
This
will
prevent freezing with

resulting
damage to the seals. Should the vehicle be
stored for any period of time, coat
these
surfaces

with
light grease to prevent rusting.

M-11.
AXLE
SHAFT
INSTALLATION

Refer
to Fig. M-2.

Installation
of the front right and
left
axle shaft
is the same and is given in the following
paragraphs.

a.
Clean
all parts of
dirt
and foreign matter.

b.
Enter
universal joint and axle shaft assembly

in
the axle housing, taking care not to knock out
the inner oil seal.
Enter
the splined end of the
axle shaft
into
the differential and push
into
place. 281

FRONT
AXLE

FIG.
M-l
1—FRONT
STEERING

KNUCKLE

(With
Spicer Universal Joint)
1—
Wheel
Hub Cap

2—
Driving
Flange Cap Screw

3—
Axle
Shaft Drive Flange Gasket 4—
Wheel
Bearing Cup
5—
Front
Wheel Spindle
6—
Brake
Drum
7—
Front
Brake
Cylinder

8—
Brake
Backing Plate

9—
Pivot
Pin Bearing Cap
10—
Pivot
Pin Bearing Cap Nut
11—
Pivot
Pin 12—
Pivot
Bearing Adjusting Shims

13—
Pivot
Pin Cone and Rollers
14—
Steering
Knuckle
Oil Seal 15—
Front
Axle Universal Joint
16—
Thrust
Washer
17—
Brake
Backing Plate Screw
18—
Brake
Shoe and
Lining

19—
Hub
Oil Seal
20—
Wheel
Hub Bolt Nut
21—
Wheel
Bearing Cone and Rollers 22—
Wheel
Bearing Washer

23—
Wheel
Bearing Retaining Nut
24—
Wheel
Adjusting Nut
Lock
Washer
25—
Wheel
Bearing Retaining Nut
26—
Snap
Ring

c.
Install
the wheel bearing spindle and bushing.
d.
Install
brake backing plate.
e.
Grease and assemble wheel bearings and oil

seal.
Install
the wheel hub and drum on the wheel
bearing
spindle.
Install
the wheel bearing washer
and
adjusting nut. Tighten nut with
Wrench
W-144
as shown in
Fig.
M-5, until there is a slight drag on the bearings when the hub is turned.
Then
back off approximately one-sixth of a
turn.
Install
lock

washer
and nut, tightening nut
into
place, and then bend lip of lock washer over on the locknut.
f.
Install
drive
flange
and gasket on hub and attach
with
six cap screws and lock washers.
Install
snap

ring
on outer end of axle shaft.

g.
Install
hub cap.
h.
Install
the wheel, lug nuts, and wheel disc.
i.
If
tube
was installed with axle assembly on
vehicle, check front wheel alignment (Section O),
bleed brakes (Section P), and lubricate front axle

universal
joints (Section B).

M-12.
FRONT
AXLE
INSTALLATION

To
install the front axle, reverse the procedures described in
Par.
M-4 and then perform the follow­
ing operations:

a.
Torque spring clip plate (U-bolt) nuts securing the axle to the front springs, (see Par. M-4).

b.
Adjust and bleed the brakes (see Section P).

c.
Check
axle lubricant level and
fill
as necessary, (see Section B).

d.
Check
front end wheel alignment (see Section
O).
e.
Check
wheel turning angle. Refer to Par. M-14.
M-13.
Steering
Tie Rod and
Bell Crank

These
parts of the front axle are covered in Sec­
tion O.
M-14.
4-Wheel Drive
Turning
Angle

Adjustment
and service information regarding
turning
angles
is covered in Section O.

M-15.
2-WHEEL-DRIVE
FRONT
AXLE
The
front axle is of the reverse
Elliot
type. It is a
steel forging, heat treated for strength and ma­
chined
to
close
limits. The steering knuckles are
mounted on pins which pass through
openings
at each end of the
"I"
beam and are locked securely

in
position with tapered pins and nuts. The knuckles

ride
on
ball
thrust bearings for
ease
of steering. See
Figs.
M-12, M-13.

The
knuckles are connected by a tie rod which is
mounted on
ball
and socket connections. The tie

rod
is adjustable to secure correct
toe-in
of the front wheels. A steering connecting rod
connects

the
left
knuckle arm with the steering gear arm.

Standard
caster and camber of the front
wheels
are
built
into
the front axle. Wheel camber cannot
be changed however, caster can be adjusted by

placing
tapered shims or
wedges
between
the
springs and spring seats. For
complete
information

regarding
the steering
geometry
refer to the
Section O.

M-16.
Removal of Solid
Front
Axle

Note:
The procedure for removing the solid front
axle varies slightly, depending on whether the
springs are slung under or over the axle. These

variations
are
noted
in the following procedure.

a. -
Raise the front end of the vehicle and safely support the frame behind the springs.

b.
Remove the
wheels
by removing the wheel
discs and lug nuts.

c.
Disconnect the steering connecting rod at the
ball
and socket connection on the steering knuckle. 282

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

M
FIG.
M-12—FRONT
AXLE—EARLY
MODEL
DJ-5, DJ-6
1— Outer Bearing Cone and Rollers
2— Outer Bearing Race
3—
Inner
Bearing Cone and Rollers
4—
Inner
Bearing Race 5— -Wheel Brake Cylinder
6— Bleeder Screw 7— Upper Expansion Plug
8— Steering Knuckle Pin
9— Steering Knuckle Bushing
10—
Lubrication
Fitting Opening
11—
Front
Axle I-Beam 12— Steering Knuckle Pin Bearing 13—
Brake
Backing Plate
14—
Brake
Drum 15—
Brake
Shoe

16— Wheel Hub Bolt
17— Spindle
18—
Front
Wheel Hub
19— Spindle Nut
d. Disconnect the shock absorbers at the axle

mounting
pads.
e. Disconnect the brake hydraulic
hoses
at the
connections
between
front brake
lines
and
flexible
hoses.

f. Support the axle assembly on a jack, ready for removal. g. On
vehicles
with the springs slung over the axle,

remove
the
nuts
from the spring to axle U-bolt clips,

remove
the spring clip
plates,
and slide the axle as­

sembly
from underneath the vehicle.

On
vehicles
with the springs slung under the axle,
remove
the
nuts
from the spring clips and
remove

the spring clip
plates.
Then
disconnect
the spring

FIG.
M-13—FRONT
AXLE, LATE
MODEL
DJ-5, DJ-6
1— Steering Knuckle
2— Steering Knuckle Bushing
3—
Key

4— Steering Arm
5—
Lock
Spring
6—
Oil
Seal Retainer 7—
Oil
Seal
8—
Tapered
Pin
9— Dust Cover
10— Nut
11— Cotter Pin
12— Tie
Rod
13— Axle Tube 14— Plug
15— Steering Knuckle Pin
16—
Shim

17—
Thrust
Bearing
18— Bolt
19— Nut 20— Nut
21— Cotter Pin 11660
283