1953 JEEP DJ Service Manual

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

J J-20
TRANSMISSION
SERVICE
DIAGNOSIS

SYMPTOMS
PROBABLE
REMEDY

Lock
in Two
Gears
Replace
Poppet
or Shift Levers

Slips
Out of High Gear Transmission Misaligned with Bellhousing

End
Play in Main Drive Gear Damaged Pilot Bearing or Front Bearing.

Slips
Out of Second
Worn
Gear Replace
Weak
Poppet
Spring Replace

Noise
in Low Gear
Gear
Teeth Worn Replace Gears
Shifting
Shoe
Bent Replace
Shoe
Lack
of Lubrication Drain and Refill

Grease
Leak into Bellhousing Gasket Broken Front Bearing Retainer Replace
Transmission Main Drive Gear Oil Seal Replace Align Transmission Case to Bellhousing
and Bellhousing to Engine
Tighten Front Retainer
Replace
J-21.
TRANSMISSION
SPECIFICATIONS

HURRICANE
F4
ENGINE
3-SPEED

Vehicle:
CJ-3B,
CJ-5,
CJ-5A,

CJ-6,
CJ-6A
DJ-5,
DJ-6
Make
Type

Speeds

Ratios: —
First
Second

Third

Fourth
Warner

T90C

Synchronous Mesh
3 Forward — 1 Reverse
3.339
to 1 1.551 to 1 1.000 to 1
Warner

T96

Synchronous Mesh
3 Forward — 1 Reverse
2.605
to 1 1.630 to 1
1.000 to 1
Reverse
Interlock
Poppet
Clearance. . .
3.798
to 1

3.536
to 1
.001" to .007"

[0,025
a 0,178 mmJ

DAUNTLESS
V-6
ENGINE
3-SPEED

Vehicle:
CJ-5,
CJ-6,
CJ-5A,
CJ-6A

DJ-5,
DJ-6
Late
CJ-5, CJ-6
Make
Warner
Warner Warner

Model
AS7
T86AA

AS9
T86AA
T14A

Type..
Synchromesh
Synchromesh Synchromesh

Speeds
3 Forward — 1 Reverse 3 Forward — 1 Reverse 3 Forward — 1 Reverse
Ratios: —
First
2.798
to 1
2.798
to 1
3.100 to 1

Second
1.687 to 1 1.687 to 1 1.612 to 1

Third
1.000 to 1
1.000 to 1 1.000 to 1
Reverse
3.798
to 1
3.798
to 1 3.100 to 1 257

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

Jl
FOUR-SPEED
TRANSMISSION

Contents

SUBJECT
PAF.

GENERAL.
Jl-1

FOUR-SPEED
TRANSMISSION
REMOVAL.
Jl-2
Four-Speed Transmission
Disassembly
.
Jl-3 Four-Speed Transmission Control Housing
Disassembly
Jl-4
Four-Speed Transmission Reassembly Jl-5
SUBJECT
PAR.
Four-Speed Transmission Control Housing
Reasse mbly Jl-6

Transfer
Case Adapter Plate Oil Seal .
.
Jl-8
Four-Speed Transmission Installation Jl-7

FOUR-SPEED
TRANSMISSION
SPECIFICATIONS.
.
.
Jl-10

SERVICE
DIAGNOSIS
Jl-9 10771

FIG.
Jl-1—FOUR-SPEED
TRANSMISSION

1—
Control
Housing Gasket
2—
Control
Housing Assembly
3— Mainshaft Assembly
4—
Thrust
Washer
5—
Thrust
Washer
6— Reverse Shifting
Shoe
7— Reverse Shifting Arm
8—
C-Washer

9— Reverse Shifting Arm Pivot
10—
O-Ring

11— Reverse Idler
Gear
Assembly
12— Snap Ring
13—
Thrust
Washer
14—
Sleeve

15— Bearing Rollers
16— Spacer
17— Reverse Idler
Gear

18— Pipe Plug
19— Countershaft Gears 20— Bearing Rollers
21— Spacer 22— Spacer
23—
Thrust
Washer

2
4
—Bellhousi ng-to-Transmission Adapter Plate
25— Bearing Retainer
26— Bearing Retainer Bolt
27— Bearing Retainer Lockwasher
28— Bearing Retainer Gasket
29—
Main
Drive
Gear

30— Bearing Rollers 31— Transmission Case
32— Adapter Plate Lockwasher
33— Adapter Plate Capscrew
34— Side Opening Cover Gasket
35— Side Opening Cover Bolt
36— Side Opening Cover Lockwasher
37— Side Opening Cover 38— Countershaft
39— Shifting Arm Pivot Taper Pin
40— Bearing
41— Snap Ring
42—
Oil
Seal 43— Spacer
44— Reverse-Idler
Gear
Shaft 45—
Lock
Plate
46—
Lock
Plate Lockwasher
47—
Lock
Plate Bolt
48— Gasket
49— Adapter Plate 50— Adapter Plate Lockwasher
51— Adapter Plate Bolt
52— Cotter Key
53— Nut 54— Washer
55— Gasket 259

Jl

FOUR-SPEED
TRANSMISSION
J1-1.
GENERAL

A
model T-98 four-speed transmission with a cane- type shift is optional on 'Jeep* Models CJ-5 and
CJ-6
equipped with the Hurricane F4
engine.
A model T-18 four-speed transmission is optional on
the 'Jeep* Model
CJ-5
equipped with the Dauntless
V6
engine.
These transmissions provide four
speeds

forward
and one reverse with synchromesh
engage­
ment in second,
third,
and fourth speed.

For
quick identification, the optional
4-speed
transmission is 11%"
[30,16
cm.] long whereas the

standard
3-speed
transmission is 8"
[20,32
cm.] long. However the instructions for removal and
installation of the two transmissions are the same.

J1-2.
Four-Speed
Transmission Removal Use the procedure outlined under the heading,
"TRANSMISSION
REMOVAL"
Section J Par.

J-6.
FIG.
Jl-2—FOUR-SPEED TRANSMISSION MAIN DRIVE
GEAR

1—
Snap
Ring
3—Bearing 5—Main
Drive
Gear

2—
Snap
Ring
4—Washer 6—Bearing Rollers

FIG.
Jl-3—T-98
FOUR-SPEED TRANSMISSION MAIN SHAFT 1—
Blocking
Ring

2—
Direct
and
Third
Clutch
Sleeve

3—
Snap
Ring

4—
Spring

5—
Shifting
Plate
6—
Direct
and
Third
Clutch
Hub 7—
Third
Speed
Gear
Assembly
8—
Snap
Ring
9—Thrust
Washer
10—
Bearing
Rollers

11—
Second Speed
Gear

12—
Spacer
13—
Mainshaft

14—
Blocking
Ring

15—
Shifting
Plate
16— Poppet
Spring
17—
Ball

18—
Low
and Second
Clutch
Hub 19—
Retaining
Ring

20—
Low
and Second Speed
Gear
21—
Second Speed
Synchronizer
Assembly
22—
Direct
and
Third
Synchroniser Assembly 260

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

Jl

1—
Blocking
Rir

2—
Direct
and 1

3—
Snap
Ring

4—
Spring

5—
Shifting
Plat

6—
Direct
and 1 7—
Third
Speed
J1-3
4-Speed Transmission Disassembly

•
Refer to Fig. Jl-1.

Note;
The
models
T-98 and T-18 four-speed
transmission are similar in design with exception of
the second
speed
gear-to-mainshaft arrangement.
In
the model T-18 transmission, the second
speed

gear is a slide fit on the mainshaft, whereas in the
model T-98 transmission roller bearings and a
spacer are required in this area. Refer to Figs. Jl-3
and
Jl-4.

a.
Remove the transmission to transfer case adapter plate and gasket. Remove the oil seal from
the plate and, if damaged, discard the seal.
b. Remove the transmission control housing as­
sembly. Refer to paragraph Jl-4 for its dis­
assembly.
c. To make certain the two blocking rings, direct-

and-third
clutch hub, and direct-and-third clutch
sleeve
will
be assembled in their original relation­

ship,
mark them with a quick drying lacquer or an
electric pencil. Also mark the blocking ring, low-
and-second clutch hub, and the low-and-second
speed
gear.

d.
Slide the low-and-second
speed
gear toward the rear of the transmission case.
e.
Disengage
the reverse shifting arm and reverse shifting
shoe
from the reverse idler gear. Remove
the arm from the reverse shifting arm pivot.
f. Move the low-and-second
speed
gear
into
neutral position.
g. Remove the bearing retainer and gasket.
Remove the snap rings from the main drive gear
and
the outer race of the ball bearing.

h.
With a bearing puller, remove the main drive
gear ball bearing. 1436S
i
Hub

Gear

izer
Assembly

ironizer
Assembly
i.
Remove the oil slinger.

j.
Remove the snap ring from the outer bearing
race
of the transmission mainshaft ball bearing.
k. With a bearing puller, remove the mainshaft

ball
bearing.

Note:
It may be necessary to drive the mainshaft

rearward
by striking the end of the main drive gear with a lead hammer to get sufficient clearance
to install the bearing puller plates.

I.
Slide the direct-and-third clutch
sleeve
to the

rear
(third
speed)
position. Separate the mainshaft
assembly from the main drive gear. Be careful
not to
lose
any of the mainshaft pilot bearing
rollers.

m.
Lift
the mainshaft assembly out of the top
of the transmission case.

n.
Remove the main drive gear from the trans­
mission case.
o. Remove the mainshaft bearing rollers from the gear.
p.
Mark
relationship
between
synchronizer hubs

and
the splines on the mainshaft.
q. Begin disassembly of the main shaft assembly by removing the snap ring which holds the direct

and
third synchronizer assembly on the mainshaft,

r.
Remove the front blocking ring from the front
of the shaft.
s. Slide the direct-and-third-synchronizer assembly

and
the third-speed-gear assembly off the main-shaft.
t. Remove the snap ring at the rear of the main-
shaft. Slide the second synchronizer assembly and the blocking ring off the mainshaft.

FIG.
Jl-4—T-18
FOUR-SPEED TRANSMISSION MAINSHAFT ASSEMBLY
ng 8—Snap
Ring
15—Ball

third
Clutch
Sleeve
9—Thrust
Washer 16—Low and Second
Clutch
10—
Second
Speed
Gear
17—Retaining
Ring

11—
Mainshaft
18—Low and Second Speed
te 12—Blocking
Ring
19—Second Speed
Synchroni

rhird
Clutch
Hub 13—Shifting Plate 20—Direct and
Third
Synch

Gear
Assembly 14—Poppet
Spring
261

Jl

FOUR-SPEED
TRANSMISSION
U.
On the T-98 transmission remove the snap rings
holding the thrust washer, bearing rollers, second-

speed
gear, and spacer on the mainshaft. Slide
these
components
off the shaft. Refer to Fig. Jl-3.

Note:
The second
speed
gear in the T-18 trans­
mission is a slide fit
onto
the mainshaft and
does
not contain roller bearings or a spacer.
v. If the synchronizer assemblies are to be dis­
assembled and serviced proceed as follows:
Wrap

the
second-speed
synchronizer assembly in a cloth
to prevent losing the lock balls and springs. Push the clutch hub out of the low-and-second-speed
gear in a direction
opposite
the shift fork
groove.
Remove the cloth.
Lift
the balls, springs, and
plates out of the hub.
w. Remove the lockplate for the countershaft and
reverse idler gear shaft.

x.
Use a pry bar in the
slot
of the reverse idler gear
shaft to
loosen
the shaft.
Then,
slip the reverse

idler
gear shaft out of the housing and gear.
Lift
the reverse idler gear assembly from the transmission case.
y. To remove the countershaft, use a heavy brass
drift
and drive the countershaft toward the
rear
of
the transmission case. When the countershaft end
is just about even with the inside of the trans­ mission case, use a dummy shaft to force it the
remainder of the way. (Since a dummy shaft is a
FIG.
Jl -5—FOUR-SPEED TRANSMISSION CONTROL PARTS

1—
Shift
Lever

2—
Control
Housing Pin

3—
Shift
Handle
4—
Control
Housing Cap 5—
Washer

6—
Control
Lever
Spring
7—
Breather
Assembly
8— Reverse Shift
Rail

9—
Shift
Rail
Interlock Plunger

10—Expansion
Plug 11—
Low
and Second Shift
Rail

12—
Shift
Rail
Interlock Pin
13—
Direct
and
Third
Shift
Rail

14—
Control
Housing
15—
Shift
Rail
Poppet Spring
16—
Shift
Rail
Poppet
Ball

17—
Lockwire
18—
Low
and Second Shift
Fork
19—
Lock
Pin
20—
Shift
Rail
End 21—
Direct
and
Third
Shift
Fork

22— Reverse Plunger
23— Reverse Plunger Spring
24— Reverse
Rail
End
25—
Cotter
Pin
26— Reverse Plunger Poppet Spring
27— Reverse Plunger Poppet
Ball
28—
C-Washer
262

'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

Jl

FOUR-SPEED TRANSMISSION

FIG.
Jl-7—SNAP
RING
AND
THRUST WASHER INSTALLATION—T-98 ONLY
1—
Thrust
Washer

2—
Snap
Ring

placing
the shaft in a vise (with
soft
metal covering the jaws) so that the threaded end of the shaft is
up.
Install
snap ring and thrust washer at the
forward
end of the
second-speed
gear position.
See Fig. Jl-7.
Install
thrust washer with the recessed side covering the snap
ring.

Note:
The second
speed
gear in the T-18 trans­ mission is a slide fit
onto
the mainshaft and
does

not contain roller bearings or a spacer.

On
model T-98 transmission, place a rubber band
around
the
second-speed
gear bearing surface on
the shaft.
Install
the thirty-four bearing rollers Fig.

Jl-3
around the shaft. See Fig. Jl-8.
Install
spacer on the shaft.
With
the tapered shoulder of the

second-speed
gear up, slide gear on the shaft far

enough
to hold the bearing rollers in place. Remove the rubber band and slide the gear down
onto
the

thrust
washer.
Install
the
rear
snap ring and the
blocking ring
onto
the tapered shoulder of the gear.
f.
Install
the
second-speed
synchronizer assembly
on the mainshaft.
Line
up the marks made at the
time of disassembly.
Install
the snap
ring.

g.
Install
the third-speed gear assembly on the
shaft with the tapered shoulder to the front.
Slide
the direct-and-third synchronizer assembly
onto
the mainshaft, lining up the marks made at
the time of disassembly.
Install
snap
ring.

h.
Install
main drive gear assembly with roller
bearings in place in front of case.
Install
mainshaft
FIG.
Jl-8—SECOND-SPEED
GEAR

ASSEMBLY—T-98 ONLY
1—
Spacer
3—Rubber
Band

2—
Bearing
Rollers
4—Thrust
Washer

assembly through top of case, making sure roller
bearings are not knocked out of place,
i.
Temporarily install main drive gear bearing

retainer
to support drive gear.
Install
snap ring on mainshaft bearing and press bearing on shaft

and
into case until snap ring is seated against case,

j-
Remove the main drive gear bearing retainer,
install
the oil slinger on the drive gear.
Install
the snap ring on the main drive gear bearing.
Then

press the bearing on the shaft and into the case.
Install
the thickest of the four available snap
rings that
will
fit into the
groove
on the main

drive
gear shaft.

k.
Slide main drive gear bearing retainer on the
shaft and hold tightly against transmission.
With

a
feeler
gauge,
measure the distance
between
the
retainer
and the case. Select gaskets that
will
be .003" to .005"
[0,076
a 0,127 mm.] thicker than
space
between
retainer and case.
Install
gaskets
and
retainer.

I.
Complete assembly of transmission.
Check

condition of
rear
oil seal and gaskets.
J1-6. Four-Speed
Transmission Control

Housing Reassembly
Reassembly of the control housing is the reverse of disassembly. Make sure lock pins are installed in
both shift forks.
Install
new expansion plugs in base of the housing. Inspect the transmission

breather
for damage and replace if necessary. 264