1953 JEEP DJ checking oil

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

Dl
Dl-65.
Rocker Arm Cover Cleaning
and Inspection

a.
Clean
both rocker arm covers with suitable
cleaning solvent and dry thoroughly.

b.
Inspect each rocker arm cover visually for

scratches,
bends, dents, and tears. Replace cover

if
unserviceable.

Dl-66.
Timing Chain
and
Sprocket Inspection

Inspect
the timing chain and both sprockets for
damage or excessive wear. Replace unserviceable
parts.

Dl-67.
Timing Chain Cover Cleaning and Inspection

a.
Clean
the timing chain cover with suitable clean­
ing solvent and dry with compressed air.

b.
Inspect the cover visually for breaks,
cracks,
and
other damage.
With
a straightedge, check cylinder
block, water pump, and oil pump faces for bends

and
distortion.

c.
Install
oil pump gears in oil pump cavity of
timing gear cover.
With
a straightedge and feeler
gauge,
check gear and clearance. Refer to Fig.

Dl-30.
Clearance
should be
between
.0023"
[0,0584

mm.] and .0058"
[0,1358
mm.]. If it is lower
than
.0018" [0,0457 mm.], inspect thrust surfaces
of cover which touch gears for wear.

d.
Replace the timing chain cover if unserviceable.
FIG.
Dl-30—CHECKING
OIL
PUMP
GEAR

END
CLEARANCE

1—
Feeler
Gauge
2—
Straight
Edge

3—
Pump
Body
4—
Pump
Gears
Dl-63.
Oil Pump Cleaning and
Inspection

a.
Clean
gears with suitable cleaning solvent and

dry
thoroughly. Inspect for wear, scoring, and other damage. Replace either or both gears if unservice­
able.

b.
Remove the oil pressure relief valve cap, spring

and
plunger. Refer to Fig. Dl-31. Oil filter bypass
valve plunger and spring are staked in place and should not be removed. 12719

FIG.
Dl-31—OIL
PUMP
PRESSURE
RELIEF
VALVE

1—
Valve
Cap
2—
Gasket

3—
Spring

4—Valve
5—
Oil
Pump
Cover
c.
Wash valve parts thoroughly. Inspect the relief
valve plunger for wear or scoring.
Check
the spring to see that it is not worn or collapsed. Replace any
relief
valve spring that is questionable. Thoroughly

clean
the screen staked in the cover.

d.
Insert the relief valve plunger into its bore in
the cover. The plunger should have no more clear­ ance than an easy slip fit. If there is any perceptible
sideways movement, the plunger and/or the cover should be replaced.
e.
Check
oil filter bypass valve plunger for
cracks,

nicks,
or warping. The plunger should be flat and free of nicks or scratches.
f.
Lubricate
and install pressure relief valve plung­
er
and spring in bore of oil pump cover.
Install

cap and gasket. Torque cap to 30 to 40 lb-ft. [4,1 a 5,5 kg-m.]. Do not over-tig1 n.

Note:
Pressure relief valve cap has no tapped
hole

for installation of oil pressure switch.

H1
-69.
Crankshaft Vibration
Damper
Inspection

Inspect
the crankshaft vibration damper for
cracked,
broken, distorted, or otherwise damaged
condition. If damaged, replace.

Dl-70.
Crankshaft Pulley Inspection

Inspect
the crankshaft pulley for damage or exces­
sive wear. Replace if visibly worn or damaged.

Dl-71.
ENGINE REASSEMBLY

The
engine
assembly procedure in the following
paragraphs
is given in the sequence to be followed
when the
engine
is being completely overhauled.
Individual
inspection,
repair,
and fitting operations
previously covered in detail are made throughout
the assembly procedure. The assembly procedure
does
not cover accessories. If a new cylinder block
fitted with pistons is used, many of the operations

will
not be required.

Mount
the cylinder block in an
engine
repair stand.
If
an
engine
stand is not available, perform the
following assembly operation in a manner designed to protect personnel against an accident, and the
engine
and its parts against damage. 95

H

ELECTRICAL
SYSTEM SUBJECT
PAR.

Directional
Signal
Lamps
H-138

Hazard
Warning
Lamps
H-139

Head
Lamp
Replacement H-130
Head
Lamp
Aiming Procedure H-131 Headlight Dimmer Switch H-127

License
Plate
Lamp
H-136
Main
Light
Switch. H-126

Marker
Lights .H-l40

Parking
and
Turn
Signal
Light
H-133
Stop
Light
Switch. H-l28
Tail,
Stop and
Turn
Signal
Lamp
.H-134

H-1. GENERAL
All
'Jeep' Universal vehicles are equipped with 12- volt electrical systems. Use caution around the higher
voltage
of the 12-volt system as accidental

short
circuits are more capable of damaging electri­
cal
units. Also, arcs around the 12-volt battery are
more apt to ignite any gas that may be escaping

from
it. In the following paragraphs
will
be found
information about the battery, distributor, coil,
generator, alternator,
voltage
regulator and start­ ing motor. These units with the connecting wires,

make
up the
engine
electrical system. The wiring
diagram
will
show the different circuits of the en­

gine
electrical system and the various units which
make
up
those
circuits.

With
plastic-covered wiring harnesses use only

rubber-insulated
wiring clips.

Caution:
All current production vehicles are 12- volt, negative ground. Whenever servicing a 12-
volt electrical system, use caution, as an accidental

short
circuit is capable of damaging electrical units. Disconnect battery ground cable before changing

electrical
components.

H-2.
Battery

The
battery is a storage reservoir for electrical
energy produced by the alternator or generator.
The
battery should store sufficient energy for
operation of the entire electrical system when the
alternator
or generator is not pr 1,scing output,

such
as when the ignition is first turned on. Of

particular
importance is maintaining the electrolyte
at the correct level, regularly checking with a
hydrometer, and maintaining clean, tight cable connections.

Battery
service information is given in this section.

Caution:
Do not allow flames or sparks to be
brought near the vent
openings
of the battery since
hydrogen gas may be present in the battery and might explode.

Note:
The liquid in the battery (electrolyte) is a
solution of sulphuric acid which, on contact, can

injure
skin or
eyes,
or damage clothes. If it is spilled
on the skin or spattered in the
eyes,
promptly flush
it
away with quantities of clear water only. If the

acid
is spilled on clothes, wet it thoroughly with a

weak
solution of ammonia, or with a solution of sodium bicarbonate or baking soda.
SUBJECT
PAR.

HORN
H-137

ELECTRICAL
COMPONENT
REPLACEMENT
H-150

WINDSHIPLD
WIPER SYSTEM
H-141
thru
149

SERVICE
DIAGNOSIS.
. .H-151

ELECTRICAL
SPECIFICATIONS
H-152

Caution:
When installing the battery, the nega­
tive terminal must be grounded. Reverse polarity of the battery can cause severe damage to the charg­ing system.

Battery
Inspection

a.
Check
the specific gravity of the electrolyte in
each cell of the battery. A hydrometer reading of 1.260 indicates that the battery is fully charged.

If
the reading is 1.225 or below, the battery
needs

recharging.
If one or more cells is 25 "points" (.025) or more lower than the other cells, this in­
dicates that the cell is shorted, the cell is about to

fail,
or there is a
crack
in the battery partition in
the case. Unless the battery is repaired or replaced, battery trouble
will
soon
be experienced.

b.
Check
the electrolyte level in each cell, add

distilled
water to maintain the solution [9,5 mm.] above the plates. Avoid overfilling. Replace
the filler caps and tighten securely. It is important to keep the electrolyte level above the plates at all
times because plates that are
exposed
for any
length of time
will
be seriously damaged.

c.
Check
the wing nuts on the hold-down frame for tightness. Tighten them only with finger pres­

sure,
never with pliers or a wrench. Excessive
pressure
could damage the battery case.

d.
Clean
the battery terminals and cable con­ nectors. Prepare a strong solution of baking soda

and
water and brush it around the terminals to
remove any corrosion that is present. The cell caps must be tight and their vents sealed to prevent
cleaning solution entering the cells. After cleaning,
connect cables to battery and coat the terminals

with
heavy grease.

e.
Inspect the battery cables and replace if badly
corroded
or frayed.
Check
tightness
of terminal
screws to ensure
good
electrical connections.
Check

the
tightness
of the negative ground cable con­nection at the frame to ensure a
good
ground
connection.
f.
Load
test
the battery. Connect a voltmeter across the battery. Run the starting motor for 15 seconds. If the
voltage
does
not drop below 10
volts the battery is satisfactory. If the
voltage
falls
below the figure given, yet the specific gravity is
above
1.225,
the condition of the battery is questionable.
g. Be sure the
engine
ground strap connection, 172

H

ELECTRICAL
SYSTEM

14365

FIG.
H-5—WIRING
DIAGRAM—F4
ENGINE
CURRENT
MODEL
1—
Left
Headlamp

2—
Left
Parking and Signal Lamp
3—
Right
Parking and Signal Lamp

4—
Right
Headlamp
5—
Marker
Lamp
— Amber
6—
Generator
7—
Distributor

8—
Ignition
Coil

9— Starting Motor
10— Battery Ground Cable
11—
12
Volt
Battery

12—
Flasher
(Directional Signal)
13— Instrument Cluster
A—Hi-Beam
Indicator

B—Auxiliary
C—Instrument Lights
D—Oil
Pressure
Indicator
E—Charging Indicator
F—Temperature Indicator
G—Fuel
Gauge
Indicator
H—Instrument Voltage Regulator
14—
Ignition
and
Starter
Switch
15—
Horn
Button 16—
Directional
Signal Switch 17— 4-Way
Flasher
Switch
18—
Flasher
(4-Way)
19—
Windshield
Wiper Motor Switch
20—
Main
Light
Switch

21—
Fuel
Gauge
Tank
Unit

22—
Back-Up
Light
Switch
23—
Marker
Lamp — Red 24—
Right
Tail
and Stop Lamp
25—
Right
Back-Up Lamp
26—
Left
Back-Up Lamp
27—
Right
Tail
and Stop Lamp
28—
Marker
Lamp — Red 29— Stop
Light
Switch
30— Foot Dimmer Switch

31—
Windshield
Wiper Motor Assembly

32—
Voltage Regulator
33— Temperature Sending
Unit

34—
Oil
Pressure
Sending
Unit

35— Spark
Plugs
&
Cables

36—
Horn

37— Junction Block
38—
Marker
Lamp — Amber
through a
two-position
push-pull switch located on
the
left
side
of the control panel.
The
foot-operated
headlight dimmer switch is
mounted on the floorboard to the
left
of the steering
column.

H-9.
PRESTOLITE
DISTRIBUTOR
—
DAUNTLESS
V-6 and

HURRICANE
F4
ENGINE

The
Prestolite distributor on the F4
engine
is
mounted on the right
side
of the
engine
and is op­
erated by a coupling on the oil pump shaft, see Fig.
D-l,
which is driven by a spiral gear on the cam­
shaft. The spark advance is fully automatic, being controlled by built-in centrifugal
weights.
The Pres­

tolite
distributor on the V-6
engine
(Fig. H-8) is mounted at the
left
front of the
engine
on the tim­
ing chain cover. It is driven by a spiral gear on the
camshaft. The spark advance is fully automatic,
being controlled by built-in centrifugal
weights,
and by a vacuum advance system. While
some
parts of the distributor may be checked or replaced
with the unit mounted on the
engine,
it is
best
to periodically remove it for a thorough check. Infor­ mation covering the parts which can be serviced
without removal is
given
below.
The
Prestolite distributor installed on the V-6 en­

gine
is similar in construction to the distributor in­
stalled on the F4
engines
except
for the addition of

a
vacuum advance mechanism.
The
same checking procedures outlined in Par. C- 10a, are used for the Prestolite V-6 distributor with

exception
of specifications.
H-10. Distributor Cap

The
distributor cap should be inspected for cracks,
carbon runners and
evidence
of arcing. If any of

these
conditions
exists, the cap should be replaced.
Clean
any corroded high
tension
terminals.

H-11.
Rotor
Inspect the rotor for cracks or
evidence
of
excessive

burning at the end of the metal strip.
After a distributor rotor has had normal use the
end of the rotor will
become
burned. If burning is found on top of the rotor it indicates the rotor is
too short and
needs
replacing. Usually when this condition is found the distributor cap
segment
will 178

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

H

12746

FIG.
H-l8—VACUUM
ADVANCE
MECHANISM
(DELCO)

A—Full
Advance

B—No
Advance
1—Vacuum
Pull
Rod
e.
To adjust breaker point cam dwell and set tim­
ing of engine, refer to
Pars.
C-10 and
C-ll.
H-31. Coil
— V-6 Engine

The
sealed coil
does
not require any special service
other than keeping the terminals and wire connec­
tions clean and tight.

The
positive (+) terminal of the coil is connected
to the ignition switch through the ballast resistor,
and
is also connected directly to the starter
sole­

noid to by-pass the resistance during cranking of
engine.
The
negative (—) terminal is connected to the

distributor.
The secondary (high tension) terminal
is connected by a short cable to the center terminal
in
the distributor cap.

Always
make certain the coil wires are connected to the proper coil terminals to ensure correct
coil
polarity.

Note:
The ignition coil and ballast resistor must
be of the same manufacturer. Ballast resistors
and
ignition coils of one manufacturer are inter­changeable with both units of the other. H-32.
Ballast
Resistor

•
V-6 Engine.

An
ignition ballast resistor is in series with the
primary
winding of the coil. The ballast resistor
helps regulate the flow of
primary
current through­
out the speed range. At low
speeds
when the con­
tacts remain closed longer, the ballast heats and
increases in resistance, thereby limiting the flow of

primary
current. At higher
speeds
when the con­
tacts remain closed for shorter periods of time, the ballast
cools
and thereby decreases in resistance
to allow more
primary
current and reduce the
fall

off
in
available voltage.
During
starting, the resistor compensates for the lowered battery
voltage
re­
sulting from the starter load and permits an in­ crease in
primary
current, resulting in a higher
secondary
voltage
for starting.
The
only
test
required of the ignition ballast re­
sistor is a continuity check. Characteristics of the ballast produce wide variations in resistance with
changes in ballast temperature. Therefore, check­ ing
voltage
drop across the ballast would be mis­
leading.

Caution:
Never make a connection that connects
the ballast across the battery as this
will
burn
the ballast resistor winding.

H-33.
Spark
Plugs

Clean
and gap
spark
plugs as described in
Par.
C-4.
Inspect them for excessive burning and erosion of
electrodes, blistering of porcelain at the firing tip,

black
deposits, or fouling. These conditions indicate
that the plugs have not been operating at the cor­

rect
temperature.

Note:
Prolonged idling just before removing and
checking the plugs should be avoided as it may
produce false indications.

Spark
plug operating temperatures may have been
too hot, too cold, or normal as described.

a.
At too hot a temperature, the tip of the insulator
will
show
dark
spots
and blisters after fairly short service. As high-temperature operation is con­
tinued, the whole insulator
nose
will
discolor, show­
ing fused and blistered
deposits
near the electrode
as well as considerable erosion and burning of the
electrodes. After extreme service, the porcelain it­ self may be fused, cracked, and blistered at the tip.

The
electrodes
will
show extreme erosion and
burn­

ing and possibly even surface cracking.

Note:
If such cracking appears on certain plugs
after fairly short service, it may be caused by water
leaks in the associated cylinders.
b. At too cold a temperature plug operation, in
the early
stages,
will
result in a
dull
black
sooting

of the plug.
This
condition frequently is found in new vehicles during the break-in period and is no
indication of trouble in this case. As the condition progresses, black
deposits
of oil and carbon build
up on the base of the shell and on the insulator

until,
in extreme cases, the space
between
insulator

and
shell may be almost completely filled. Excessive
electrode erosion
will
seldom be found in cases of cold plug operation. These indications can be pro­
duced by the use of an excessively
rich
air-fuel mixture and the carburetor should be checked if
this condition is suspected. Fouling
will
also be
caused by leaking rings or intake valve
guides
that
permit excessive oil to reach the combustion
chambers.
The use of a hotter plug
will
help
burn

away
some
of this fouling but the mechanical con­ dition of the
engine
should be corrected.
c. In normal temperature operation the plug
will
accumulate grayish-tan to reddish-brown
deposits

with
fairly uniform discoloration of the insulator
nose
and slight, localized electrode erosion. If the
insulator shows any blotches, blisters,
irregular
dis­
coloration, etc., look for hot-plug symptoms. Too
hot or too cold plug operation may be caused by
the use of plugs of other than the specified heat

rating
but if the plugs are as specified a hotter or 187

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

H
no soldering or unsoldering of leads; two complete

rectifying
diode assemblies
which
eliminate the need
for removing and replacing individual diodes; a
corpplete isolation diode assembly; and a rotor
assembly complete with shaft,
pole
pieces, field

coil,
and slip rings.

The
transistorized
voltage
regulator is an electronic
switching device. It
senses
the
voltage
appearing
at the auxiliary terminal of the alternator and
supplies the necessary field current for maintaining
the system
voltage
at the output terminal. The
output current is determined by the battery electri­
cal
load; such as headlights, heater, etc.

The
transistorized
voltage
regulator is a sealed

unit,
has no adjustments, and must be replaced
as a complete unit.

H-64. ALTERNATOR
PRECAUTIONS

The
following precautions must be observed to
prevent damage to the alternator and regulator.

a.
Never reverse battery connections. Always

check
the battery polarity with a voltmeter before

any
connections are made to be sure that all con­
nections correspond to the battery ground polarity of the vehicle.

b.
Booster batteries for starting must be properly
connected. Make sure that the negative cable of
the booster battery is connected to the negative

terminal
of the battery in the vehicle. The positive
cable of the booster battery should be connected
to the positive terminal of the battery in the
vehicle.

c.
Disconnect the battery cables before using a fast charger.

d.
Never use a fast charger as a booster for

starting
the vehicle.

e.
Never disconnect the
voltage
regulator while
the
engine
is running.

f.
Do not ground the alternator output terminal.
g.
Do not operate the alternator on an open
circuit
with
the field energized.

h.
Do not attempt to polarize an alternator.

These
precautions are stated here as an aid to

service
personnel. They are also restated at appro­

priate
places in the
text
of this section of the
manual.

H-65. ALTERNATOR
CHARGING
SYSTEM SERVICE
Important:
All alternator
tests
for the 35, 40 and
55 amp alternator are the same, however, there is a
difference
between
the location of the various ter­

minals
and field current specifications. The field

current
of the 35 amp alternator should be 1.7 to 2.3 amps, 40 and 55 amp alternators should be 1.8
to 2.4 amps, with
full
battery
voltage
applied to
the filed coil. Disassembly and assembly procedures

are
the same for all three alternators.
Terminal
locations and wire harness color
codes
for the 35,
40 and 55 amp alternator are shown in Fig. H-38.

H-66.
Service Diagnosis

In
diagnosing a suspected malfunction of the

alternator
charging system, consideration must
be given to the complete electrical power plant of the vehicle; including the alternator, regulator,
ignition switch, charge indicator lamp, battery,

and
all associated wiring. If it is suspected that the

alternator
is not fully charging the battery and

fulfilling
the electrical requirements of the electrical
system, several checks should be made before

checking
the alternator itself:

Note:
Whenever service is required in connection

with
an alternator problem, the first
step
should be to verify that the wiring harness hook-up is correct
as indicated in Fig. H-38.

a.
Test the condition of the battery and
state
of
charge
(Par. H-2).
If the battery is not fully charged
and
in
good
condition, use a replacement battery
for making alternator system
tests.

Caution:
Make certain that the negative battery

post
is connected to ground when making the
battery installation. Serious damage to the alter­

nator
can result if battery polarity is reversed.

b.
Check
fan belt for proper tension (Par.
C-27).

Caution:
To increase belt tension, apply pressure
to alternator front housing only as permanent damage can result if pressure is applied to
rear

housing.

H-67.
Alternator In Vehicle Tests

The
following
tests
are made with the alternator

in
the vehicle with output and regulator connec­
tions maintained to the alternator except as noted

in
Fig. H-27 and H-28. The field plug and
voltage
regulator are disconnected for
these
tests.
The

tests
are given in proper order and detail in the
following paragraphs.

a.
Isolation Diode Test: To determine if the isola­
tion diode is open or shorted, refer to Par. H-69.

b.
Alternator Output Test: To isolate the trouble
to the alternator or regulator, refer to Par. H-70.

c.
Alternator
Field
Circuit
Test: To determine the condition of the field
circuit
(brushes and rotor),

refer
to Par. H-73.

d.
Brush
Insulation
and Continuity
Test:
To deter­
mine the condition of the
brush,
refer to
Par.
H-75.

e.
Rotor In-Vehicle Test: To determine whether
the rotor coil is open or shorted, refer to
Par.
H-73.
f. Any further
tests
must be conducted with the

alternator
removed and disassembled. When this
is done, the condition of the rotor, the rectifying

and
isolation diodes, and the stator can be further
tested.

A
commercial alternator tester Sun
Electric
Model

VAT-20
or equivalent can be used to make all
necessary
tests
on the alternator system. If a com­

mercial
tester is used, follow the recommended
testing procedure outlined by the tester manu­

facturer.
If
a commercial tester is not available, follow the
testing procedure as outlined in this manual.

H-68.
Test Equipment

a.
Volt Ampere Tester such as Sun
Electric
Model

VAT-20
or equivalent with meter ranges as shown

in
the following list can be used. 195

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

H
13406

FIG.
H-39—STARTING
CIRCUIT

1—
Ground
Cable
2—
Battery

3—
Positive Cable
4—
Alternator
Wire
5—
Alternator

6— Ignition Switch
Wire

H-93.
Maintenance Procedure

A
periodic inspection should be made of the start­ ing circuit. Since the interval
between
these
checks

will
vary according to the type of service, it should, under normal conditions, be made every 500 hours
of operation. Inspect all starting circuit wiring for damage.
Check
for
loose
or corroded terminals and
for dependable operation of the starting motor.

H-94.
Wiring

Refer
to Fig. H-39. Inspect the starting circuit to make sure that all
connections are clean and tight.
Check
for worn or damaged insulation on the wires. Perform a volt­

age-loss
test
to make sure there is no
loss
of start­ ing motor efficiency resulting from high resistance
connections. Voltage
loss
from the battery ter­
minal
to the starting motor terminal should not
exceed .30 volts for each 100 amperes. Voltage
loss
between
the battery ground
post
and the start­ing motor frame should not exceed .10 volts for
each 100 amperes. If the
voltage
loss
is greater
than
these
limits, measure the
voltage
loss
over
each part of the circuit until the resistance causing the
voltage
loss
is located and corrected.

H-95.
Commutator
Sluggish starting motor operation may be caused by a dirty commutator or worn brushes. The com­mutator cannot be cleaned while the. starting motor is mounted on the
engine
and it
will
be necessary
to remove it and proceed as for an overhaul. Should 7— Ignition Switch
8— Solenoid
Wire

9—
Starter

10— Solenoid
11—
Connector
Strap
the commuator be rough or worn, it should be
removed for cleaning and reconditioning.
H-96.
Overhaul Procedure

At
periodic intervals the starting motor circuit
should be thoroughly checked and the motor re­ moved from the
engine
for cleaning and checking.

H-97.
Removal and Disassembly

Refer
to Fig. H-40 and H-41.
To
remove the starting motor from the engine, dis­
connect the leads and cover the battery lead ter­

minal
with a piece of
hose
or tape to prevent short

circuiting.
Remove the flange
bolts
holding the starting motor to the flywheel housing. Remove
the starting motor from the vehicle.

Each
part of the starting motor should be removed, cleaned, and inspected for evidence of wear or
damage. The Bendix
Folo-Thru
Drive should be
cleaned and inspected for evidence of wear or a distorted spring. Bearings should be checked for
proper clearance and fit. All insulation should be
free of oil and in
good
condition. The armature,
field coils, and brushes should be checked for
good
ground and lack of open circuits.

H-98.
Brushes

a.
The brushes should slide freely in their holders
and
make full contact on the commutator. Worn
brushes should be replaced.
b.
Check
brush spring tension with a spring scale.
Hook the scale under the brush spring near the 203

H

ELECTRICAL
SYSTEM

11035

FIG.
H-40—PRESTOLITE STARTING MOTOR—F4 ENGINE 1— End
Plate

2—
Plug

3—
Thrust
Washer
4—
Brush
Plate Assembly 5— Screw
6—
—Lock
Washer
7—
Insulating
Washer
8—
Terminal

9—
Field
Coil
and Pole
Shoe
Set
10—
Frame

11—
Insulating
Washer

12—
Washer

13— Nut 14—
Lock
Washer

15—
Insulating
Bushing

16—
Pole
Shoe
Screw
17— Sleeve Bearing
18—
Drive
End Frame
19—
Intermediate Bearing

20—
Bendix
Drive

21—
Screw

22—
Lock
Washer

23—
Thrust
Washer

24— Key
25—
Armature

26—
Thru
Bolt

27—
Insulator

brush
and
pull
On
a line parallel with the side of
the
brush.
Take
the
reading
just as the spring leaves the
brush.
It is important that the brush spring
tension be kept within the limits specified at the end of this section. If the tension is too low, there

will
be a loss of efficiency from poor brush contact.
Too
great a tension
will
cause excessive brush and
commutator wear. To change the tension, twist the

spring
at the holder with long-nosed pliers,

c.
Worn
brushes should be replaced. Brushes that
are
soldered to the field coil should be unsoldered

and
the
loop
in the field coil lead should be opened.
Insert
the new brush pigtail to its
full
depth in the
loop. The new brush lead should be tightly clinched

in
the terminal and then soldered to make a strong, low-resistance connection.

H-99.
Commutator

Check
the commutator for wear and discoloration.
If
the commutator is rough or worn the armature should be removed and the commutator turned
down in a lathe. A discolored commutator should
be cleaned with carbon tetrachloride. Never use
emery cloth.

H-100.
Armature

Visually
inspect the armature for mechanical
defects
before checking for shorted or grounded
coils. Use a set of
test
probes for testing armature

circuits.
To
test
the armatures for grounds, touch
one point of the
test
probes to a commutator seg­
ment and touch the other point to the core or shaft. Do not touch the points to the bearing surface or
to the brush surface as the arc formed
will
burn

the smooth finish. If the lamp lights, the coil con­ nected to the commutator segment is grounded.
To
test
for shorted armature coils, a growler as
shown-in Fig. H-42 is necessary. The armature is placed against the core and a steel strip is held
on the armature. The growler is then energized 204

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

H
H-111.
Brushes

Check
brush length. If brushes are worn to one-

half
their original length, replace them. Also check
for
cracks,
chips, damaged mounting holes, oil

saturation,
or other damage; replace brushes.

H-112.
Commutator

Check
the commutator for wear and discoloration.
If
the commutator is rough or worn the armature
should be removed and the commutator turned
down in a lathe. A discolored commutator should
be cleaned with carbon tetrachloride and inspected.

Scratches
on the commutator may be removed

with
sand paper. Use compressed air to remove

sand
particles after cleaning.

H-113.
Armature

Visually
inspect the armature for mechanical

defects
before checking for shorted or grounded
coils. Use a set of
test
probes for testing armature

circuits.
To
test
the armature for grounds, touch
one point of the
test
probes to a commutator
seg­
ment and touch the other point to the core or shaft.
Do not touch the points to the bearing surface or
to the brush surface as the arc formed
will
burn
the smooth finish. If the lamp lights, the coil con­
nected to the commutator
segment
is grounded.

H-114.
Field
Coils

Using
test
probes, check the field coils for both ground and open circuits. To
test
for ground, place
one probe on the motor frame or
pole
piece and
touch the other probe to the field coil terminals.
If
a ground is present, the lamp
will
light.

To
test
for open circuits, place the probes on the
field coil terminal and on an insulated
brush.
If
the light
does
not light, the coil is open circuited.

H-115.
Brush
Holder Inspection

Inspect
brush
holders for distortion, wear, and other
damage.
Check
that brush holders pivot freely on

their
pivot pins.
Check
brush spring tension with

a
spring scale. Hook the spring scale under the
brush
holder at the brush and
pull
on a line
paral­

lel
to the side of the
brush.
Note
scale reading just
as brush leaves commutator. Tension must be 35 oz. [9,925 kg.] minimum. Replace brush springs
if
tension is insufficient.

H-116.
Solenoid
Coils

Check
solenoid coil as follows:

a.
Remove screw from motor terminal of solenoid

and
bend field coil leads away from terminal.
Con­
nect terminal to ground with a heavy jumper wire.
See
Fig.
H-48.

b.
Connect a 12-volt battery, a high-current
vari­

able resistance, and an ammeter of 100 amperes

capacity
in series
between
S terminal of solenoid

and
ground; battery negative is to be connected
to ground. Connect a heavy jumper wire from
solenoid base to ground terminal of battery.
Con­

nect a voltmeter
between
base of solenoid and

small
S terminal of solenoid. Refer to Fig. H-48.
12455

FIG.
H-48—TEST CONNECTIONS,
STARTER
SOLENOID
COIL
1— S
Terminal

2—
Solenoid

3—
Ground
Connection 4—Voltmeter 5—Ammeter
6—
12-Volt
Battery
7—
Ground
Connection*
c.
Slowly decrease resistance until voltmeter
read­

ing increases to 10 volts.
Note
ammeter reading.

This
is current drawn by both windings in
parallel
;

it
should be 42 to 49 amperes at 10 volts, with solenoid at room temperature.

d.
Disconnect jumper wire from motor terminal
of solenoid. Increase resistance until voltmeter

reads
10 volts;
note
ammeter reading.
This
is
cur­

rent
drawn by hold-in winding only; it should be 10.5 to 12.5 amperes at 10 volts, with solenoid at
room temperature.
e. If solenoid windings do not rest within specifi­ cations given, replace solenoid switch assembly.

H-117.
Starting Motor Reassembly

a.
Lubricate
shift lever linkage and fasten in drive housing with lever stud.

Caution:
Do not lubricate solenoid plunger or solenoid cylinder.

b.
Install
return spring on solenoid plunger and

insert
plunger into solenoid cylinder. Apply sealing
compound on both sides of solenoid flange where it

extends
between
drive housing and field frame.

Attach
plunger to shift lever with fulcrum pin.

Fasten
solenoid to drive housing with two mount­
ing screws.

c.
Lubricate
armature shaft with silicone grease.
Install
assist spring and drive assembly on shaft

with
pinion outward.

d.
Install
pinion
stop
retainer on armature shaft

with
recessed side outward. Place a new snap ring on drive end of shaft and hold it in place with a
hard
wood block. Strike block with hammer to
force snap ring over end of shaft; slide the ring
down into
groove
in shaft. See Fig. H-49, left hand view. 209