1953 JEEP CJ clutch

fuel cap release gearbox fuel fill door release audio recommended oil warning light

Page 263 of 376

$JEEP CJ 1953 Service Manual Jeep* UNIVERSAL SERIES SERVICE MANUAL Jl necessity for assembly, one should be made at this time to assist on disassembly. One can be made by using a \Y%N [2,86 cm.] diameter steel rod cut$

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

Jl
necessity for assembly, one should be made at this
time to assist on disassembly. One can be made by
using a \Y%N [2,86 cm.] diameter steel rod cut to

9.850*
{25,02
cm.] long.
Break
sharp
edges
with a
mill
file.) Keep the dummy shaft in contact with
the countershaft at all times to prevent dropping
the bearing rollers or thrust washers,

z.
With
the dummy shaft in position, place the
transmission
case on its side and carefully
roll
the countershaft gear cluster out of the case,

aa.
Complete the disassembly by removing the dummy shaft, thrust washers, four
sets
of bearing
rollers,
and spacers.

bb.
To disassemble the reverse idler gear assembly,
remove one of the snap rings and tap out the

washers,
both
sets
of bearing rollers, center spacer,
and
sleeve.
Remove the remaining snap
ring.

J1-4.
4-Speed
Transmission
Control
Housing
Disassembly

•
Refer to Fig. Jl-5.

The
gearshift lever, spring, and spring seat were previously removed for removal of the transmission

from
the vehicle.

a.
Remove the lock pins from the gearshift forks

and
gearshift rod ends. Remove the expansion plugs
from
the front and
rear
of the gearshift lever base. Remove back-up light switch.

b.
Remove the center (third and high) gearshift

rod
first. Drive this gearshift rod out the
rear

of the gearshift lever base. As the gearshift rod is
withdrawn
from the center section of the gearshift base, remove the interlock pin from the cross
over
hole
in the gearshift rod. Before the gearshift
rod
is removed from the center section of the gear
shift base, place a finger over the
hole
to prevent

loss
of the
ball
and spring.
Then
remove the rod.

c»
Remove the low- and second-speed gearshift rod
in
the same manner.

d.
Remove the gearshift rod lock balls and springs

and.
with a piece of
wire,
push the two gearshift rod
interlock
plungers out of the pockets in the center
section of the gearshift base.

In
the reverse gearshift rod end is a spring-loaded
plunger which prevents the
driver
from accidentally
shifting into reverse gear. Should this part require
servicing,
proceed as follows:
Remove the cotter key from the rod end assembly

and
at the same time hold a finger over the
hole

to prevent
loss
of the spring.
Then
shake out the
spring
and
ball.
Compress the plunger and spring

until
the C-washer
groove
just clears the end of
the casting. Remove the C-washer.

J1-5.
4-speed
Transmission Reassembly •
Refer to Fig. Jl-1.
Assemble the unit in the reverse order of dis
assembly noting the following points:

a.
Assemble the countershaft assembly with the
fabricated
dummy shaft. The bronze front thrust

washer
and the steel backed bronze
rear
thrust
washer
should be coated with stiff lubricant and
installed
with the lugs
engaged
in the notches

in
the end of the gear cluster. Place the assembly
in
the transmission case and install the counter
shaft from the
rear,
keeping the countershaft and
dummy shaft in contact to prevent dropping

bearing
rollers or washers. Tap the countershaft
lightly into position in the front of the case but
do not seat it until the reverse idler gear assembly

and
shaft have been installed in the case.

b.
Install
the reverse idler gear shaft in the case

until
the lock plate slot is adjacent to the slot in
the countershaft. Insert the lock plate in the
slots

of the shafts making sure the plate ends are square

with
the slots.
Install
the lock plate screw and
lockwasher
to act as a pilot while tapping the
shafts alternately into position in the case. Tighten
the lock plate screw securely.

c.
Begin assembly of the second speed synchronizer assembly (see
Fig.
Jl-6) by installing the low-and
-

second-speed clutch hub in the low-and-second-
speed gear.
Install
the retaining ring in the speed gear.
Install
the retaining ring in the low and
FIG.
Jl
-6—ASSEMBLING
SECOND-SPEED

SYNCHRONIZER
1—
Low
and Second
Clutch
Gear

2—
Ball

3—
Low
and Second
Clutch
Hub
4—
Shifting
Plate
second speed gear. Slide the hub out of the gear

in
the direction
opposite
the shift fork
groove

until
the
holes
in the hub are clear of the gear.
Install
the shifter plates and springs. Push the
hub back into the gear until the springs touch the

internal
teeth
of the gear. Push one of the shifter
plates toward the center of the gear while installing

ball.
See
Fig.
Jl-6 .
This
will
hold the
ball
in position.
Install
the other two balls in the same manner.

Be
careful when rotating the assembly to prevent the hub from slipping out of the gear. When the

balls
are installed, push the hub into the gear

until
the balls snap into the neutral position.

d.
Assemble the
direct
-
and
-
third
synchronizer as
sembly in accordance with the instructions given

in
Section J, Par.
J-lle.

e.
Start
assembly of the mainshaft assembly by 263

Page 268 of 376

JEEP CJ 1953 Service Manual
TRANSFER
CASE

FIG.
K-1—TRANSFER
CASE
—
TWO
SHIFT
LEVERS

1— Companion Flange
2—
Brake
Drum 3— Emergency Brake
4—Operating Lever
5—
Oil
Seal 6—
Lever
Stud 7—
-R

Page 269 of 376

JEEP CJ 1953 Service Manual
FIG.
K-2—TRANSFER CASE
— ONE
SHIFT
LEVER

1— Companion Flange and Oil Seal
Guard

2— Emergency Brake Drum
3— Emergency Brake 4—
Brake
Operating Lever
5—
Bearing
Cap Ofl Se

Page 270 of 376

JEEP CJ 1953 Service Manual
K

TRANSFER
CASE

FIG.
K-3—UNIVERSAL JOINT FLANGE
PULLER
1—
U-Joint
Flange
Puller
W-172

2—
V-Joint
Flange Holding
Wrench
C-3281

FIG.
K-4—TRANSFER CASE SHIFT LINKAGE
CJ-5

K

TRANSFER
CASE

FIG.
K-3—UNIVERSAL JOINT FLANGE
PULLER
1—
U-Joint
Flange
Puller
W-172

2—
V-Joint
Flange Holding
Wrench
C-3281

FIG.
K-4—TRANSFER CASE SHIFT LINKAGE
CJ-5A,
CJ-6A

1—Linkage
Adjustment
loosen
the gear and remove the gear. When separat
ing the two housings, use care that the transmission

main
shaft bearing, which bears in both housings,

remains
in the transmission case.

K-3.
Transfer
Case
Disassembly
•
Refer to Fig. K-1, K-2.

To
remove the gears and bearings from the trans
fer
case on the bench, the following procedure is
recommended.

a.
Remove output shaft nuts and washers using

Yoke
Holding
Wrench,
C-3281. Remove
rear
out
put shaft companion flange with brake drum (if
FIG.
K-5—BEARING CONE REMOVING WEDGE

1— Wedge W-139

2—
Cone
and
Roller
so equipped) and front output shaft yoke, using

Tool
W-172.

b.
Remove cover bolts, lockwashers, and
bottom

cover.

c.
Remove the lockplate screw, lockwasher, and

lock
plate.

d.
Use a brass punch to drive out intermediate shaft to the
rear
of the case. Do not
lose
the thrust
washers located at each end of the gear shaft.
e. Remove the intermediate gear, two thrust

washers,
needle
bearings, and spacers,
thru
the
bottom
of the case.
f. Remove the
poppet
plugs, springs, and balls on both sides of front bearing cap. Shift front wheel
shift lever to
engaged
position (shaft forward).
g. Remove the screws, lockwashers, holding the front bearing cap. Remove the cap as an assembly

including
the clutch shaft, bearing, clutch gear,
fork,
and shift rod. Use care not to
lose
the inter

lock
which floats
between
the shift rods.

h.
Remove the screws, lockwashers holding the

brake
backing plate assembly (if so equipped)
and
rear
output cap with
speedometer
gear as
sembly. Remove entire unit as an assembly.

i.
Use a rawhide hammer to drive against the front
end of output shaft to drive the
rear
bearing cup

from
the case. Use Tool W-139, as shown in Fig.
K-5,
to
wedge
front bearing
cone
and roller as
sembly from its seat on the shaft. Place Tool
W-141,
Fig. K-6, on the output shaft
between
the
front bearing and output shaft gear. Use a rawhide

hammer
to drive against the
rear
end of the output shaft to remove front bearing cup from the case.

Loosen
snap ring and slide it forward on the shaft.

Drive
the shaft
thru
the
rear
of the case. As the shaft is removed, gears, snap
ring,
and thrust washer

will
remain in the case and can be removed from 270

Page 271 of 376

JEEP CJ 1953 Service Manual
Jeep
UNIVERSAL SERIES SERVICE
MANUAL

K
the
bottom.
Remove
rear
bearing
cone
and roller
assembly from the shaft by striking the end of the
shaft lightly against a
wooden
block,
j.

Page 273 of 376

JEEP CJ 1953 Service Manual
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 an

'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

Page 302 of 376

JEEP CJ 1953 Service Manual
N

REAR
AXLE a.
Place the transmission in neutral.

b.
Raise one wheel off the floor and place a block

in
front and at the
rear
of the
opposite
wheel.

c.
Apply a torque wrench to the a

N

REAR
AXLE a.
Place the transmission in neutral.

b.
Raise one wheel off the floor and place a block

in
front and at the
rear
of the
opposite
wheel.

c.
Apply a torque wrench to the axle shaft nut of
the elevated wheel.

d.
Turn
wheel with torque wrench. Disregard

breakaway
torque and observe torque required to
continuously
turn
wheel smoothly. Torque should
read
40 lb-ft [5,53 kg-m.] or more.

N-23. Powr-Lok
Differential Disassembly
/
and Reassembly

Refer
to
Figs.
N-38 and N-39.
The
procedure for overhauling disc type
Powr-Lok

differentials is as follows:

a.
Remove axle shafts following procedure de
scribed
in Par. N-2.

b.
Remove housing cover and gasket.

c.
Remove the
Powr-Lok
differential from the axle.
Do not remove the ring gear or bearing
cone
and

rollers
unless replacement is to be made.
Mark
the hearing cups so they may later be reassembled

with
the same bearing cones.
Mark
the differential
case halves for correct alignment at reassembly.
Each
pinion mate cross shaft should also be marked
so that each pin cam surface
will
match with the
same
V-ramp
in the case when reassembled.

d.
Separate the case halves. e. Remove the disc and plate
sets.
The illustration
(Fig.
N-39) shows the arrangement of plates and

discs.
When reassembling unit, discs and plates must be reinstalled in this arrangement. Be sure
to keep in mind which way the set
will
face toward the case.

^®(j)(j)CD©
® /'Ml
I
11
11 v

FIG.
N-39—PLATE
ASSEMBLY
ORPER
A—Model
44
B—Model
27 1—
Case
5—Disc

2—
Belleville
Plate
6—Thin
Plate

3—
Belleville
Disc
7—Sidegear
Ring

4—Plate
8—Side
Gear
f. Remove the pinion mate cross shafts, bevel
pinion mate gears, bevel side gears, and side gear

rings.

g.
Clean
all parts thoroughly in kerosene and dry

with
compressed air.

h.
Inspect all parts. Replace any items which ap

pear
to be worn or damaged.

i.
Inspect the plate surfaces of the case halves, the
side gear rings, and the clutch friction plates and
discs for excessive wear or scoring.

j.
Inspect the pinion mate shaft and ramp
sur

faces on the case for excessive wear and pitting,

k.
Inspect the pinion gear races that bear on the
side gear rings.

I.
Inspect the corresponding surfaces on the side
gear rings.

m.
Inspect the clutch plates and discs for cracks

and
distortion. In the
event
one or more of the

clutch
plates or discs
needs
replacing, replace the
entire stack of plates and discs on each side of
the pinions. These stacks are supplied in
sets.

The
differential case halves are not serviced. Should replacement be required, it is necesary to replace
the complete differential.

n.
Assemble the clutch friction plates, clutch
fric

tion discs, and dished plates on the splined hub of each bevel side gear. Make sure the plates and
discs are installed in the proper relationship as shown in Fig. N-39. The dished plates in the plate

and
disc set are always assembled with the convex
side toward the case. As each part is reassembled

in
its proper position, it is necessary that it be lightly coated with
Powr-Lok
lubricant,

o.
Place each differential case
half
on its side and
install
the side gear rings with the plates and discs
assembled. The side gear ring
will
rotate with a slight drag when properly located in the case,
p.
With
the ring gear flange
half
of the differential
case in an upright position, assemble the bevel side gears, pinion mate cross shafts, and bevel pinion
mate gears.
Install
the remaining case
half
on the
ring
gear flange half. Make sure that all markings
coincide.

q.
Install
the differential case
bolts
and
turn
them

in
a few threads.

r.
Using axle shafts from the vehicle, align the
splines of the side gear, and the side gear
ring,

s.
With
these
axle shafts in position, tighten the

differential
case
bolts
evenly. Torque 35 to 45 lb-ft. [4,84 a 6,22 kg-m.].
t. Remove the axle shafts.

u.
Check
for proper assembly.
Each
pinion mate
cross shaft should be tight on its
ramp.
If there is

clearance
between
the cross shaft and the
ramp,

the clearance should be no more than .005" [0,127 mm.].

This
clearance should be equal on all four cross
shaft ends.
v. Reinstall the unit in the axle.

w.
Install
axle shafts as described in Par. N-2.
Other
service operations such as ring gear and
pinion replacement, or pinion and bearing adjust ments, are performed in the same manner as de- 302

Page 303 of 376

JEEP CJ 1953 Service Manual
Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

N
scribed
in
Pars.
N-ll through N-l9 for standard
axles, with the exception of the following torque
recommendations. Torque the differential case
b

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

N
scribed
in
Pars.
N-ll through N-l9 for standard
axles, with the exception of the following torque
recommendations. Torque the differential case
bearing
cap screws 70 to 90 lb-ft. [9,7 a 12,4 kg-m.]

and
the cover screws 15 to 25 lb-ft. [2,1 a 3,4
kg-m.].
The ring gear screws on axles with Powr-

Lok
differentials should be torqued as follows:

Model
30 and 44 axles 35 to 55 lb-ft. [4,84 a 7,60 kg-m.].

N-24. TRAC-LOK DIFFERENTIAL
As
optional equipment
Trac-Lok
Model 44 differen
tial
is available on all Jeep Universal vehicles equipped with semi-float flanged axle shafts.
A
conventional differential transmits all of the
ring
gear torque through the differential gears to the axle shafts. Torque is at all
times
equal on the axle shafts, and if one wheel slips, the other wheel

can
only put out as much torque as the slipping
wheel.

The
Trac-Lok
differential is similar,
except
that

part
of the torque from the ring gear is trans mitted through clutch packs
between
the side gears

and
differential case. The multiple disc clutches

with
radial
grooves
on the plates and concentric
grooves
on the discs are
engaged
by a preload

from
Belleville springs, plus separating forces from
the side gears as torque is applied through the
ring
gear.

The
Trac-Lok
construction permits differential action when required for turning corners and transmits equal torque to both
wheels
when driving

straight
ahead. However, when one wheel tries to spin due to leaving the ground, a patch of ice,
etc., the clutch packs automatically provide more
torque to the wheel which is not trying to spin.
It
can be
seen
then that the
Trac-Lok
differential
resists wheel spin on bumpy roads and provides
more pulling power when one wheel tries to slip.
In
many cases of differences in traction, pulling
power
will
be automatically provided until both
wheels
start to slip.

In
diagnosis of vehicle operators' complaints, it
is important to recognize two things:

a.
If, with unequal traction, both
wheels
slip, the

Trac-Lok
has
done
all it can possibly do.

b.
In extreme cases of differences in traction, the
wheel with least traction may spin after the
Trac-

Lok
has transferred as much torque as possible
to the non-slipping wheel.
N-25.
Lubrication

The
Trac-Lok
differential requires a special
lubri

cant
and ordinary multipurpose gear lubricants

MUST
NOT be used. Use only 'Jeep* Differential
Oil,
Part
No. 94557.

Trac-Lok
differential may be cleaned only by disassembling the unit and wiping with clean rags. Do not flush the
Trac-Lok
unit.

Note:
The
Trac-Lok
differential is serviced at the
same time intervals as the standard differential.
N-26.
Trouble
Symptoms

If
noises
or roughness, such as chatter, are present
in
turning corners, the probable cause is incorrect

or
contaminated lubricant.
Before any differential is removed and disassem
bled for chatter complaints, the correctness of
lubri

cant
can and should be determined.

A
complete
lubricant
drain,
and
refill
with specified

Limited
Slip Differential lubricant
will
usually
correct
chatter.

The
following procedure is recommended to ensure

complete
removal of old lubricant.

a.
Warm
the lubricant by vehicle road operation,

or
5 minutes of operation in gear at 30 mph with
both
wheels
off the ground on a hoist.

Caution:
Never place the transmission in gear with
the
engine
running when only one wheel of a

Limited
Slip Differential equipped vehicle is raised.
The
vehicle might drive itself off the
jack
and produce damage or
injury.

b.
Drain
lubricant while
warm.
Remove
drain
plug

or
cover to
drain
completely. If cover is removed,

it
may be necessary to replace gasket at this time.

c.
Refill
axle with specified
Limited
Slip Differen

tial
lubricant.

d.
Operate the vehicle for approximately ten miles
[16,09
km.], making at least ten figure 8 turns
to flush the old lubricant out of the clutch packs.

e.
Repeat
steps
b, c, and d, making sure to replace
the cover gasket if required in
step
c.
f. It is possible that slight chatter, requiring ad
ditional
vehicle operation, may remain after
step
e. If chatter persists after 100 miles
[160,9
km.]
of vehicle operation, or remains severe after
step

e above, disassembly and repair
will
be necessary.
N-27.
Unit
Inoperative

Proper
performance and capabilities of
Limited
Slip
Differentials are
often
misunderstood. No
precise
methods
of measuring
Limited
Slip Dif

ferential
performance are generally available in the field. A functioning unit can be determined by
relatively
simple vehicle operational
tests,
as
follows:

a.
Place one wheel on
good
dry pavement, and the
other on ice, mud, grease, etc.

b.
Gradually
increase
engine
rpm to obtain maxi

mum
traction
prior
to "break-a-way." The ability
to
move
the vehicle
effectively
will
demonstrate

proper
performance.

c.
If extremely slick surfaces, such as ice or grease,

are
used
some
question may exist as to proper per
formance at
step
b. In
these
extreme cases a prop

erly
performing
Limited
Slip Differential
will
pro
vide greater "pulling" power by lightly applying
the parking brake.

N-23.
Trac-Lok
Differential Disassembly
and
Reassembly

It
is recommended that the
complete
axle assembly
be removed from the vehicle, when it
becomes
necessary to remove the
Trac-Lok
from the hous

ing.
Refer to Par. N-3 and N-12 for removal of axle shafts and differential case from axle housing. 303

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