Jeep CJ-2A Factory Service Repair Manual

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MECHANIC'S MANUAL A-3 FOREWORD This Service Manual is a ready reference for use of shop mechanics in the adjustment and maintenance of Willys-Overland cars and trucks, also for the Service Salesman so that he may better describe necessary repair work in his contacts with car owners. The information contained herein is not elementary as it is in- tended for Service Men who are familiar with automobile construction and repairing in general. Essential information is presented with brief descriptions, illustrationsand repair procedures. All data is in accordance with Engineering Specificationsand should be strictly adhered to in the repair and adjustments of all units. All sections of the manual are compiled in accordance with the major units of the vehicles. The sections are indicated alphabetically and the pages of each section are numbered separately to readily allow insertion of new data in the loose leaf binder as new models are produced. A detailed index is in the back of the manual. Each section covers the subject in the same general way: General Description, Removal, Conditioning, In- stallation and Adjustment. Owners are retained and developed into loyal customers or lost as a result of the satisfadon sewed in the Service Department, therefore, the success of this part of your business is of vital importance. By maintaining capable service facilities your customers are encouraged to regard your Service Department as the proper place to bring their cars for adjustments, maintenance and lubrication. Lubrication is the one service every car requires periodically. This service provides a valuable means to keep in touch with the cars sold and to contact car owners from whom you can frequently obtain prospects for both new and used car sales. - Willys-Overlandhas always recognized the value of thorough service knowledge of its products and years ago adopted the policy of field service education through the medkm of factory conducted service meetings at the factory or at distributor points. We realize that the distributors and dealers, for various reasons have been unable to send all their employees to the factory conducted meetings. Therefore, the Service Department has issued Shop Manuals for each model containing consolidated specifications. Also during the ye& general service letters and other literature containing technical data are mailed to all distributorsand dealers to aid them in servicing the products and maintain a high degree of customer satisfaction. I t is important that all your service employees read and study all service data mailed by the factory. Exper- ience has shown that most letters received at the Factory Service Department relate to some mechanical prob- lem which has already been covered in general service literature. A well organized Service ~ e~&tment is a great asset to a dealer or distributor, Customer follow-up is essential, also adequate tool equipment, uniforms for mechanics and service literature properly filed in a binder for ready reference by the mechanics. Do not overlook the advantages offered by local specialized service stations, such as Auto-Lite, Carter Car- buretor, Monroe Shock Absorber and Goodyear Tire. Occasionally it may be advisable to obtain their expert advice from these representatives to satisfy an owner's complaint. In such cases the distributor or dealer should take the car to the specialist to have the necessary work performed. The transaction with the owner should be handled as if the work was performed in your own service station. Keep customers satisfied, they are your best new car prospects for the future. Remember, a well satisfied customer is one of your greatest advertisements. WILLYS-OVERLAND MOTORS WILLYS-OVERLAND EXPORT CORP.

A-4 MECHANIC'S MANUAL

MECHANIC'S MANUAL A-5 SERVICE POLICY AND PROCEDURE NEW,CAR WARRANTY Willys-Overland New Car Warranty, Service Policy and Procedure is basically the same a s that of all other automobile manufacturers. Briefly, we warrant our cars to the original purchaser for a period of 90 days or 4,000 miles, whichever &all occur first. (See Page A-7.) FACTORY WARRANTY OBLIGATIONS -We will make good at our factory, either by duplication or credit, any parts that ow inspection proves to be faulty in workmanship or material - trade accessories ex- cepted. (Accessory adjustments are to be handled direct with the accessory manufacturer's authorized Service Station.) In addition we assume a fair labor expense for installation of major parts, such as internal motor parts, clutch, transmission, transfer case, axle parts, etc. DISTRIBUTORS AND DEALERS OBLIGATIONS - To maintain a clean, well equipped Service Sta- tion with competent service personnel. To maintain an adequate stock of spare parts. To prominently display authorized Sales and Service signs. To give each new car a thorough retail delivery inspection as outlined on the New Car Inspection Report not only for your protection but also to assure delivery of the car in perfect mechanical and operating condition. Will ys - Overland OWNER SERVICE POLICY I. DELIVERY-The heelling Dealer will super- in the United States vpon presentation of "ise the preparation of the rehide fer this Or-r Service Policy and the Coupons. delivery to the Owner in accwdance w i l l Repairs other than Warranty Sewice are to factory imtruclbnr. be <barged lor in Lc regular way. 2. OWNER'S IDENTIFICATION CARD-An Owmrr Identilcation Card will be provided to the Omer at the time of delivery of the vehicle. This will intrcduce him to any Au. thorixed Willyr-Overland Dealn and entitle him to receive mrice as set forth in thir policy. It will be of assislanceto the Owner if he will carry the Owner Identification C a r d with him at all times to facilitate his obtaining the services ollered under thir pdxy. 3. PARTS A N D LABOR-Should any original with the exception of tires. prove faully in either material or workmanship during the first 90 days after delivery (or for the fir4 4,OM) milsr. depondinq on which occur% first), the equipment will bo re. placed by any Authorized Overland Dealer in the United Stater without charge l o the Owner for material or labor. 4. I.WO A N D I.WO-MILE ADJUSTMENTS- The attached coupons entitle Le owner t o the inspectian a d adiustmentr ar fisted a b s k of the coupons. There services are given Ires by any.Willys-Overland Dealer 5. INSPECTIONS-Throughout the life el the vehicle the Owner is entitled to hare it tested and inspected without any charge every 30 days or 1 .WO miles by any Author- hgd Willy,.Orerland Dealer in the United Stater, provided such inspection or testing requires no dirmanlling of parts. 6. TOURIST PRIVILEGES - Upon +resenla- lion o l this Policy by the Ome. when IOU.- ins. any Autho.ized Willys.Omlmd Dcater in the United States will prlorm the sew- ices a, ovtlmed in paraqnphr three, lour and l v e ,eqa.dlee of xhece the vehicle may have been purchased. 7. CHANGE OF RESIDENCE -In caro the owner changes his residence f,om me locs. lion toanother below the Warranty period has expired. the Authorired Willy*Orer- land Dealer in the United Stater serving Le locality into which the owner moves will. vpon pmontation 01 this Pdicy. render m y oo-charge sewice to which the Ownet may be entitled as ovtlined in paraqraphs three. four and h e . FIG. A-1--OWNER SERGCE POLICY

A-6 MECHANIC'S MANUAL To register batteries and tires with the local authorized service stations of their respective manufacturers for owner protection under the terms of the warranties. To see that the owner receives the Owner's Service Policy and Identification Cards and that the Retail De- livery Receipt is correctly made out and mailed to the factory at time of delivery. No adjustments forparts or labor will be made if we do not have a Retail Delivery Receipt in our possession which has been completed in all detail and giving the date of delivery. To give each new car delivered the 1,000 and 2,000 mile inspections and necessary adjustments gratis, as provided in the Owner's Service Policy. To extend to transients, who present Owner's Identification Cards proving status of their car, the same cour- tesy and service extended to bwn customers. DISTRIBUTOR PARTS CLAIMS Alleged faulty parts for which adjustment is expected must be thoroughly cleaned and returned to the Factory by the distributor, with transportation charges prepaid. The parts must be correctly tagged with Return Material Tag (Form No. 144) and a Parts Claim (Form No. 145 Rev.) must be completed in full detail. These forms will be supplied gratis by the Factory upon request. When parts are shipped to the Factory, include the pink copy of the Parts Claim as a packing slip. Mail the original copy (Parts Copy) and the second copy (Service Copy) to the Factory Service Department, marked for the attention of the Claims Division. Retain the yellow copy for file reference. The Factory cannot accept claims for minor items such as gaskets, oil seals, nuts and bolts, as the cost of these items must be assumed by the Distributor or Dealer as part of their operating expense. DEALER PARTS CLAIMS F WILLYS-OVERLAND RETAIL DELIVERY RECORD FIG. A-2-RETAIL DELIVERY CARD Parts for which credit is expected must be thoroughly cleaned and tagged by the dealer and ship~ed, with transportation charges prepaid, to the distributor from whom the replacing parts were purchased. Factory Parts Claim (Form 145 Rev.) must be completed in full detail, including the distributor's invoice number on which the new parts were purchased. The dealer should retain the yellow copy of the claim for his files, include the pink copy as a packing slip when the parts are shipped and mail the Parts and Service copies to the distributor. The distributor, in turn, forwards the parts to the Factory with his own clairq, as outlined above. LABOR CLAIMS All labor claims are to be based on the time allowances published in the standard Factory Flat Rate Manual, which may be obtained gratis from a distributor or the Factory Service Department. In the event a labor claim is in order, complete the lower section of the Parts Claim (Form 145 Rev.). Fill in the Flat Rate Manual operation number, description of the labor, number of hours and total amount of the labor. A copy of the shop repair order, bearing the signature of the owner, indicating that the ,work has been satisfactorily done, must be attached to the Service copy of each labor claim. If any work was done in a Service Station other than a distributor or dealer, a paid invoice covering such work dust also be attached to the claim. All labor claims from dealers must be sent to the distributor under whom they operate, and the distributor, in turn, passes them on to the Factory. The Factory expects all dealers and distributors to adjust all unquestionable customer claims whilcn occur within the warranty period without charge, pending Factory adjustment. The Factory makes no labor allowance for installation of minor parts, tune-up adjustments, aligning of wheels, adjusting brakes or labor when parts are not replaced, unless authorized by the Factory Service Department. These items must be considered as part of a Distributor's or Dealer's operating expense. NEW CAR DELIVERY AND INSPECTION The satisfactory performance of any automobile depends largely upon the conditions in which it is elivered to the owner and usually the condition of the vehicle when delivered means the difference b tween a satisfied and a dissatisfied owner. 2

MECHANIC'S MANUAL A-7 Before delivering a new car to the new owner, give it a thorough inspection using Inspection Form 77A-001 Rev. Fig. A-3 in duplicate, as a guide to assure a properly conditioned car and as protection against possible claims. Send the duplicate copy to the Factory Service Department. Without fail complete the New Car De- livery Record, Fig. A-2, enclosed in the envelope with the Owner's Manual, and mail it to the factory, so we will have a record of each sale. Fill out both the Owner Identification Card and the Electrical Equipment Identification Card registering the latter with the Electric Auto-Lite representation. Have the battery and tires registered with the local battery and tire representation. Deliver the two identification cards and the Owner ServicePolicy to the purchaser and explain the Service Policy to prevent possible misunderstanding. Subsequent gratis inspectionswill maintain contact with the customer which will prove profitable and of great assistance in securing additional prospects for both new and used car sales. Reports (Form 77A-001 Rev.) are available gratis from the Factory Service Department. 1,000 AND 2,000 MILE INSPECTIONS The one thousand and two thousand mile inspections are of utmost importance for at that time the owner has had the opportunity to become acquainted with his car and accustomed to handling it. Any slight improve- ment that you may make in the car will be noticed by the owner with the satisfaction of receiving increased performance. When properly handled these inspections provide an opportunity to demonstrate to the new owner that you are interested in the performance of his car and will properly service it. At these times too, it is important to impress upon the owner that you desire him to return for periodic inspections each 1,000 miles (1600 km.) or at least once every two months, depending upon how the vehicle is used. When an owner buys a new car he usually invests as much money in it as possible. The inspection contacts supply a good opportunity to approach the owner on the question of accessories or other equipment if he has not purchased such equipment with his car. PERIODIC INSPECTIONS Frequent owner contact means more lubrication and equipment sales, and more prospects for car sales. It is,, good business to urge the purchaser to call a t your Service Station each 1,000 miles (1600 km.) of operation at? which time the following should be checked, at a price, to attract and encourage such inspections. (No charge INSPECTION ITEMS 1. Road test car. 2. Check wheel alignment. 3. Check tire pressure. 4. Check cooling system. 5. Adjust fan belt, if necessary. 6. Adjust clutch, if necessary. 7. Tune engine. 8. Test and refill battery. 9. Check generator charging rate. 10. Tighten body bolts. 11. Check operation of all keys. 12. Check all lights. 13. Adjust steering conn., if necessary. 14. Adjust brakes, if necessary. 15. Eliminate squeaks. 16. Lubricate chassis. 17. Service oil filter. 18. Change engine oil. F*" ,,Am, ",. SO". 4" ,... WILLYS-OVERLAND NEW VEHICLE INSPECTION REPORT Model V.hkk L.i.1 b+m Lriol Dole of Ner V.LIcI= Condilionin# 1 1 - by-. Isnilion I" Sml Tank Cw Iq sold lo .Ad&.,* Do- h&. Addr." COW OF 1HlS RE?OR1 MUSI I t YlllW 10 WIUVI-OVUUND MOIOSS. INC. IOttDO 1. OHIO. SERVICE D t I A I I M l N I , + IHYEDlA1El A n t l WE INSPlClION 1" FAClllIATE ANY WARlANlV C U M ADJUIIMINIS. 111 dun-Chd ibn. rhlxhx... fund 0.1. 2nd durn-Chd ihrn. r h k h mquimd odiusmml. Wtib in 1 . 11 . "N r h m .p.,.ti.n d.., n., .ppl" lo r.hi.1. k i ~ imp..,d. FIG. A-3-INSPECTION REPORT

A-8 MECHANIC'S MANUAL The only Warranty under which new Willys-Overland Motor Vehicles are sold is that of the Manufacturer, being the Standard Warranty recom- mended by the Automobile Manufacturer's Association, and is as follows: "This is to certify that we, WILLYS-OVERLAND MOTORS, INC., TOLEDO, OHIO, U. S. A. warrant each new motor vehicle manufac- tured by us, to be free from defects in material and workmanship under normal use and service, our obligation under this Warranty being limited to making good at our factory any part or parts thereof, including all equipment or trade accessories (except tires) supplied by the Car Manufacturer, which shall, within ninety (90) days after making delivery of such vehicle to the original purchaser or before such vehicle has been driven 4000 miles (6400 km.), whichever event shall first occur, be returned to us with transportation charges prepaid, and which our examination shall disclose to our satisfaction to have been thus defective; this warranty being expressly in lieu of all other warranties expressed or implied and of all other obligations or liabilities on our part, and we neither assume nor authorize any othkr person to assume for us any other liability in connection with the sale of our vehicles. This warranty shall not apply to any vehicle which shall have been repaired or altered outside of an Authorized Willys-Overland Service Station in any way so as, in the judgment of the Manufactur- er, to affect its stability or reliability, nor which has been subject to misuse, negligence or accident." The Manufacturer makes no warranty against, nor assumes any liability for any defect in metal or other material in any part, device or trade accessory which cannot be discovered by ordinary factory inspection. WILLYS-OVERLAND MOTORS, INC. NOTE-Willys-Overland Motors, Inc., reserves the right at any time or times to revise, modify, discontinue or change any models of its vehicles, or any part or parts thereof, without notice; and, without it or the Seller, in- curring any liability or obligation to the Purchaser.

GENERAL DATA Willys Willys Americar willy8 Jeep Jeep Station Wagon Jeep Truck Jeep Truck Jeep Station Sedan Willys Overland Willys Americar Willys Model:. ................................. Engine:. ................................. Cylinders.. .......................... Bore.. .............................. Stmke.. ............................. Displacement.. ....................... ......... Compression Ratio: Standard.. ...... High Altitude. Aluminum. ......... Truck (Pick-Up) .... Truck (Panel). ..... 48 Own 4 3-H ' 4-36" 134.2 cu. in. 5.7 to 1 .......... 6.84 to 1 5.7 to 1 5.7 to 1 39 Own 4 3%- 43h' 134.2 cu. in. 6.48 to 1 6.81 to 1 7.00 to 1 .......... .......... 4-40 Own 4 Wh' &=ha 134.2 cu. in. 6.48 to 1 6.81 to 1 7.00 to 1 6.1 to 1 5.7 to 1 4-41 Own 4 3-H ' 4-36' 134.2 cu. in. 6.48 to 1 6.81 to 1 7.00 to 1 6.1 to 1 6.1 to 1 - 15.6 63 @ 3900 rpm 61 @ , 3900 rpm 65 Q 4000 rpm 61 @ 3900 rpm 61 Q 3900 rpm 4-42 Own 4 3-Vs' 4-%' 134.2 cu. in. 6.48 to 1 6.81 to 1 ......... 6.1 to 1 6.1 to 1 15.6 63 @ 3800 rpm 61 Q 3800 rpm .......... 61 @ 3800 rpm 61 Q 3800 rpm CJ-2A Own 4 3-H' 4-3h" 134.2 cu. in. 6.48 to 1 7.00 to 1 463 Own 4 3-!h ' 4-3/sW 134.2 cu. in. 6.48 to 1 7.00 to 1 .......... .......... 6.48 to 1 15.6 63@4MN)rpm 63 Q 4000 rum .......... .......... 63 Q 4000 rpm 2-WD Own 4 3%' 4-36" 134.2 cu. in. 6.48 to 1 7.00 to 1 .......... 6.48 to 1 .......... 4-WD Own 4 3-H' 4%" 134.2 cu. in. 6.48 to 1 7.00 to 1 6-63 Own 6 3' 3-HV 148.44 6.42 to 1 .......... .......... .......... .......... .......... --- 15.6 60@40Wrpm 60 Q 4000 rpm 15.6 63 @ I 41100 rpm .......... .......... 63 @ 4000 rpm .......... 15.6 63 @ 4000 rpm Horse Power SAE:. ................... AoluPCStandUd.. ............... ........... Actual-High Altitude.. ............... Actual-Aluminum .......... Actual-Truck (Pick-Up) ........... Actual-Truck (Panel). ........... Toque: ibs.ft.-Standard.. High Altitude.. ........ ............ Aluminum Truck (Pick-Up). ....... ......... Truck (Panel) - .................. Wheelbase-Standard. :. Truck (Pick-Up) .............. Truck (Panel). ............... -- Tread: Standard--Fmnt .................. Rear. .................. Truck (Pick-UP)-Front. ........... Rear ............ .............. (Panel)-Fmnt Rear. ............. (Platform)-Fmn t ........... Rear. ........... 15.6 61 @ 3600 rpm 60 Q 3600 rpm 61 Q4000 rpm .......... .......... '15.6 61 @ I 3600 rpm 60 Q 3600 rpm 63 Q 4000 rpm 58'0 3600 rpm 48 Q 3200 rpm M) 3600 rpm 48 @, 3200 rpm 48 @ 3200 rpm IW @ 1600 rpm .......... 103 Q 1700 rpm 100 @ 1600 rpm 100 Q 1600 rpm 100" 100' 100' .......... 105 @ 2000 rpm 105 Q 2000 rpm 106 @ 2200 rpm 105 Q 2200 rpm 109 @ 2300 rpm .......... .......... 102" .......... .......... 109 @ 2200 rpm 108 Q 2200 rpm 111 Q 2300 rpm 107 8 2200 rpm 100 Q 2200 rpm 104" 100" 100" 108@ 18MIrpm 106 @ 1800 rpm 112 @ 1900 rpm 106 Q 1900 rpm 106 @ 1900 rpm 108 @ 1800 rpm 106 @, 1800 rpm .......... 106 @ 1900 rpm 106 @ 1900 rpm 105 @ 2000 rpm 105 @ 2000 rpm .......... .......... .......... 105 @ 2000 rpm 105 Q 2000 rpm .......... .......... 105 @ ZOO0 rpm 105 @ 2000 rpm 105 Q 2000 rpm .......... 105 @ 2000 rpm .......... .......... 105 @I 2000 rpm Length Overall-Passengar Can.. ......... Truck (Pick Up). ......... Truck (Panel). ........... Truck (Platform). ......... Width Overall- Passenger Can.. ......... Truck (Pick Up). ......... Truck (Panel). ........... Truck (Platform). .........

GENERAL DATR-(Continued) Model: l U - Height Overall-Passenger Can.. .......... 86%' Truck (Pick Up). .................... Truck (Panel). ...................... Truck (Platform). .................... Weight - Shipping - Sedan 2D (Standard). ... 2258 2D (SpWway). ............ 2D (Deluxe) .............. 4D (Standard). ... 2300 4D (Speedway). ............ 4D (Deluxe). ............... 4D (Plainsmen). ............ ... Coupe (Standard). 2l81 ............. (Speedway) (Deluxe). ............... (Plainsman). ............ Station Wagon.. .............. Truck (Pick Up). .... 22% Truck (Panel Del.). .. 2568 (Platform). ............. Ground Clearanc+(Standard). ... 8" (Pick-Up) .... 8' (Panel) ....... 8-8/32' (Platform) .............. Fuel TankgP~~#~enger Cars. .............. 8 Gala Trucks.. ..................... 8 Gala Cooling System.. ......................... 11 Qta - Candle Lamp Bulbs: Power Numbe Headlights .................. . . . .... 32-21 2320 Parking ............................... 1.5 55 Instrument-Standard & Speedway.. .... 3 63 -Deluxe (2). ................... .... -Tmckr. .................. 1.5 55 Beam Indicator.. ..................... 1 51 Dome ............................... 3 63 Tail and Stop ....................... 21-3 1158 ...... License. ................... .. 3 63 Spot ................................. 32 1133 Fop ..................... .... ...... 32 1133 Accmmy Switch. ..................... 1.5 51 Wae-Uflht~ Switch. .. .T ; . ....... .T;. 20 h. .......... ......... .......... 2265 .......... Pgg 2305 2200 .......... 2136 .......... 2483 221 8 2730 .......... 8" 8" 8-9h2" .......... 11-1/2 Gals. 11-W Gals. 8" .......... .......... .......... 8 Gala , ........... .......... 11-'/i Gals 11-9'2 Gala 15 Gals. 15 Gala ......... 15 Gala .......... 15 Gala 10-'/2 Gals. 8 Gals .......... lO-$$ Gala 11 Qta 11 Qta 11 Qta 11 Qta 11 Qta 11 Qta 11 Qta andle lower Numbs 12-21 2320 1.5 55 1 51 1 51 .... .... 1 51 3 63 a-3 1158 3 63 32 1133 32 1133 1.5 51 -20 Amp. - andle lower Numbel 12-21 2320 1.5 55 1 51 1 51 1.5 55 1 51 3 63 21-3 1158 3 83 32 1133 32 1133 1.5 51 nndle bwer Numbn 12-21 2320 1.5 55 1.5 55 1.5 55 3 63 1 51 3 63 21-3 1158 3 63 32 1133 32 1133 1.5 51 andle 'ower Numbe 12-21 23m 1.5 55 1.5 55 1.5 55 3 63 1 51 3 63 2l-3 1158 3 63 32 1133 32 1133 1.5 51 Candle Power Numbe 5-35 Watt 7'Sid. 3 83 Candle Power Numbe i-35 Watt 7'Sld. 1.5 85 1 51 Candle Power Numbc i-35 Watt 7" Sld 1.5 55 . . , . , , . , ........ 1 51 1 51 15 m 21-3 1158 ........ ........ ........ ........ Candle Power Numbel -35 Watt 7" Sld. 1.5 55 Candle Power Number r35 Watt 7" Sld. 1.5 55 1 51 Clrcult Breaker Circuit Breaker Circuit Br-aisr

Jeep CJ-2A Factory Service Repair Manual

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