Jeep CJ 1945-1970 Repair Information

Transmission

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REMOVAL & INSTALLATION



Except Utility Models

CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Drain the transmission and transfer case.
  4.  
  5. Remove the shift lever and shift housing. On CJ-2A models up to serial No. 38221 remove the remote linkage as follows:
    1. Remove the shift rods from the transmission and from the steering remote control clutch levers.
    2.  
    3. Remove the shift lever fulcrum pin and remove the shift lever.
    4.  
    5. Remove the toe plates from the floor pan at the steering column.
    6.  
    7. Remove the 2 screws holding the linkage housing to the steering column, and lift the housing from the positioning pin.
    8.  
    9. Remove the shift assembly down through the floor pan.
    10.  
    11. Remove the lower clutch and shift lever from the housing by turning counterclockwise.
    12.  
    13. Remove the upper clutch and shift lever in the same manner.
    14.  

  6.  
  7. Remove the set screw from the transfer case shift lever pivot pin. Remove the pivot pin, shift levers, and shift lever springs.
  8.  
  9. If the vehicle is equipped with Power Take-Off (PTO), remove the shift lever plate screws and lift out the lever.
  10.  
  11. Disconnect the front and rear driveshafts from the transfer case. If the vehicle is equipped with PTO, disconnect the transfer case end of the PTO driveshaft.
  12.  
  13. Disconnect the speedometer cable at the transfer case.
  14.  
  15. Disconnect the hand brake cable.
  16.  
  17. Disconnect the clutch cable at the bell crank.
  18.  
  19. Place jacks under the transmission and engine. Protect the oil pan with a wood block.
  20.  
  21. Remove the nuts holding the rear mount to the crossmember.
  22.  
  23. Remove the transfer case-to-crossmember bolt.
  24.  
  25. Remove the frame center crossmember-to-frame side rail bolts and remove the crossmember. Remove the transmission-to-bell housing bolts.
  26.  
  27. Force the transmission to the right to disengage the clutch control lever tube ball joint.
  28.  
  29. Lower the engine and transmission. Slide the transmission and transfer case assemblies toward the rear until they clear the clutch.
  30.  
  31. Remove the 6 screws and lockwashers attaching the transfer case rear cover and remove the cover. If the vehicle is equipped with PTO, remove the PTO shift unit.
  32.  
  33. Remove the cotter pin, nut, and washer holding the transfer case main drive gear on the rear end of the transmission mainshaft. If possible, remove the main drive gear. If that's not possible, refer to Step 19.
  34.  
  35. Remove the transmission-to-transfer case bolts.
  36.  
  37. Install a transmission mainshaft retaining plate tool W-194 to prevent the mainshaft from pulling out of the case. If this tool is not available, loop a piece of wire around the mainshaft directly in back of the second speed gear. Install the shift housing right and left bolts part way into the case. Attach each end of the wire to the bolts. Support the transfer case, and with a soft mallet, tap lightly on the end of the mainshaft to loosen the gear and separate the two units.
  38.  
  39. Join the transfer case and transmission. Remove the wire or special holding tool. Remove the shift housing right and left bolts.
  40.  
  41. Install the transmission-to-transfer case bolts. Tighten them to 35 ft. lbs. (48 Nm).
  42.  
  43. Install the main drive gear. Install the cotter pin, nut, and washer holding the transfer case main drive gear on the rear end of the transmission mainshaft.
  44.  
  45. Install the transfer case rear cover and Install the cover.
  46.  
  47. For vehicles equipped with PTO, install the PTO shift unit.
  48.  
  49. Slide the transmission and transfer case assemblies forward until they engage the clutch.
  50.  
  51. Force the transmission to the right to engage the clutch control lever tube ball joint.
  52.  
  53. Install the transmission-to-bell housing bolts. Tighten them to 30 ft. lbs. (41 Nm).
  54.  
  55. Install the frame center crossmember. Tighten the bolts to 50 ft. lbs. (68 Nm).
  56.  
  57. Install the transfer case-to-crossmember bolt. Tighten it to 45 ft. lbs. (61 Nm).
  58.  
  59. Install the nuts holding the rear mount to the crossmember. Tighten them to 40 ft. lbs. (54 Nm).
  60.  
  61. Connect the clutch cable at the bell crank.
  62.  
  63. Connect the hand brake cable.
  64.  
  65. Connect the speedometer cable at the transfer case.
  66.  
  67. Connect the front and rear driveshafts to the transfer case. If the vehicle is equipped with PTO, connect the transfer case end of the PTO driveshaft.
  68.  
  69. If the vehicle is equipped with PTO, install the shift lever.
  70.  
  71. Install the set screw in the transfer case shift lever pivot pin. Install the pivot pin, shift levers, and shift lever springs.
  72.  
  73. Install the shift lever and shift housing. On CJ-2A models up to serial No. 38221, install the remote linkage as follows:
    1. Install the upper clutch and shift lever on the housing by turning counterclockwise.
    2.  
    3. Install the lower clutch and shift lever on the housing by turning counterclockwise.
    4.  
    5. Install the shift assembly down through the floor pan.
    6.  
    7. Install the two screws holding the linkage housing to the steering column, and lower the housing onto the positioning pin.
    8.  
    9. Install the toe plates on the floor pan at the steering column.
    10.  
    11. Install the shift lever. Install the shift lever fulcrum pin.
    12.  
    13. Install the shift rods at the transmission and the steering remote control clutch levers.
    14.  

  74.  
  75. Fill the transmission and transfer case.
  76.  

Utility Models
2-WHEEL DRIVE

The following applies to models both with and without overdrive.


CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Raise and support the front end on jackstands.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the remote linkage as follows:
    1. Remove the shift rods from the transmission and from the steering remote control clutch levers.
    2.  
    3. Remove the shift lever fulcrum pin and remove the shift lever.
    4.  
    5. Remove the toe plates from the floor pan at the steering column.
    6.  
    7. Remove the two screws holding the linkage housing to the steering column, and lift the housing from the positioning pin.
    8.  
    9. Remove the shift assembly down through the floor pan.
    10.  
    11. Remove the lower clutch and shift lever from the housing by turning counterclockwise.
    12.  
    13. Remove the upper clutch and shift lever in the same manner.
    14.  

  6.  
  7. Disconnect and tag the wires at the overdrive solenoid.
  8.  
  9. Disconnect and tag the wires at the overdrive rail switch.
  10.  
  11. Matchmark and disconnect the driveshaft at the transmission or overdrive.
  12.  
  13. Disconnect the speedometer cable at the transmission or overdrive. Plug the hole.
  14.  
  15. Disconnect the overdrive control cable.
  16.  
  17. Remove the support at the rear of the overdrive. Keep the spacers together.
  18.  
  19. Remove the overdrive governor.
  20.  
  21. Place a jack under the bell housing and take up the weight of the engine. Protect the oil pan with a block of wood.
  22.  
  23. Place a floor jack under the transmission and support it without lifting the engine.
  24.  
  25. Remove the transmission-to-bell housing bolts.
  26.  
  27. Pull the transmission back about 3 / 4 in. (19mm).
  28.  
  29. Insert a thin prybar through the opening in the side of the bell housing and pry the clutch release fork from engagement with the clutch release bearing carrier.
  30.  
  31. Pull the transmission back until it clears the bell housing and remove it with the clutch release bearing carrier mounted in the main drive gear bearing retainer.
  32.  
  33. Raise the transmission and slide it into place in the bell housing. Make sure that the clutch release bearing engages the release fork.
  34.  
  35. Install the transmission-to-bell housing bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  36.  
  37. Install the overdrive governor.
  38.  
  39. Install the support at the rear of the overdrive. Keep the spacers together.
  40.  
  41. Connect the overdrive control cable.
  42.  
  43. Connect the speedometer cable at the transmission or overdrive.
  44.  
  45. Connect the driveshaft at the transmission or overdrive.
  46.  
  47. Connect the wires at the overdrive rail switch.
  48.  
  49. Connect tag the wires at the overdrive solenoid.
  50.  
  51. Install the remote linkage as follows:
    1. Install the upper clutch and shift lever on the housing by turning counterclockwise.
    2.  
    3. Install the lower clutch and shift lever on the housing by turning counterclockwise.
    4.  
    5. Install the shift assembly down through the floor pan.
    6.  
    7. Install the two screws holding the linkage housing to the steering column, and lower the housing onto the positioning pin.
    8.  
    9. Install the toe plates on the floor pan at the steering column.
    10.  
    11. Install the shift lever. Install the shift lever fulcrum pin.
    12.  
    13. Install the shift rods at the transmission and the steering remote control clutch levers.
    14.  

  52.  
  53. Connect the negative battery cable.
  54.  

4-WHEEL DRIVE

CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Drain the transmission and transfer case into a catch pan. Dispose of the fluids properly.
  4.  
  5. Remove the shift lever and shift housing.
  6.  
  7. Remove the set screw from the transfer case shift lever pivot pin. Remove the pivot pin, shift levers, and shift lever springs.
  8.  
  9. If the vehicle is equipped with Power Take-Off (PTO), remove the shift lever plate screws and lift out the lever.
  10.  
  11. Disconnect the front and rear driveshafts from the transfer case. If the vehicle is equipped with PTO, disconnect the transfer case end of the PTO driveshaft.
  12.  
  13. Disconnect the speedometer cable at the transfer case.
  14.  
  15. Disconnect the hand brake cable.
  16.  
  17. Disconnect the clutch cable at the bell crank.
  18.  
  19. Place floor jacks under the transmission and engine. Protect the oil pan with a wooden block.
  20.  
  21. Remove the nuts holding the rear mount to the crossmember.
  22.  
  23. Remove the transfer case-to-crossmember bolt.
  24.  
  25. Remove the frame center crossmember-to-frame side rail bolts, then remove the crossmember. Remove the transmission-to-bell housing bolts.
  26.  
  27. Force the transmission to the right to disengage the clutch control lever tube ball joint.
  28.  
  29. Lower the engine and transmission. Slide the transmission and transfer case assemblies toward the rear until they clear the clutch.
  30.  
  31. Remove the 6 screws and lockwashers attaching the transfer case rear cover and remove the cover. If equipped, remove the PTO shift unit.
  32.  
  33. Remove the cotter pin, nut, and washer holding the transfer case main drive gear on the rear end of the transmission mainshaft. If possible, remove the main drive gear. If that's not possible, refer to Step 19.
  34.  
  35. Remove the transmission-to-transfer case bolts.
  36.  
  37. Install a transmission mainshaft retaining plate tool W-194 to prevent the mainshaft from pulling out of the case. If this tool is not available, loop a piece of wire around the mainshaft directly in back of the second speed gear. Install the shift housing right and left bolts part way into the case. Attach each end of the wire to the bolts. Support the transfer case, and with a soft mallet, tap lightly on the end of the mainshaft to loosen the gear and separate the two units.
  38.  
  39. Join the transfer case and transmission. Remove the wire or special holding tool. Remove the shift housing right and left bolts.
  40.  
  41. Install the transmission-to-transfer case bolts. Tighten them to 35 ft. lbs. (48 Nm).
  42.  
  43. Install the main drive gear. Install the cotter pin, nut, and washer holding the transfer case main drive gear on the rear end of the transmission mainshaft.
  44.  
  45. Install the transfer case rear cover and Install the cover. If equipped, install the PTO shift unit.
  46.  
  47. Slide the transmission and transfer case assemblies forward until they engage the clutch.
  48.  
  49. Force the transmission to the right to engage the clutch control lever tube ball joint.
  50.  
  51. Install the transmission-to-bell housing bolts. Tighten them to 30 ft. lbs. (41 Nm).
  52.  
  53. Install the frame center crossmember. Tighten the bolts to 50 ft. lbs. (68 Nm).
  54.  
  55. Install the transfer case-to-crossmember bolt. Tighten it to 45 ft. lbs. (61 Nm).
  56.  
  57. Install the nuts holding the rear mount to the crossmember. Tighten them to 40 ft. lbs. (54 Nm).
  58.  
  59. Connect the clutch cable at the bell crank.
  60.  
  61. Connect the hand brake cable.
  62.  
  63. Connect the speedometer cable at the transfer case.
  64.  
  65. Connect the front and rear driveshafts to the transfer case. If equipped, connect the transfer case end of the PTO driveshaft.
  66.  
  67. If the vehicle is equipped with PTO, install the shift lever.
  68.  
  69. Install the set screw in the transfer case shift lever pivot pin. Install the pivot pin, shift levers, and shift lever springs.
  70.  
  71. Install the shift lever and shift housing.
  72.  
  73. Fill the transmission and transfer case.
  74.  

 
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