Your Operation and Care Manual Universal Jeep Model CJ-2A
Foreword IN YOUR possession is a motor vehicle that has been thoroughly tested and inspected. Like any other piece of machinery, to maintain it in first class condition, you should lubricate it at the time prescribed with the proper grade of oil and grease and keep all working parts and oil holes clean and free of dirt and grit. You should also periodically have it systematically inspected at an Authorized Willys-Overland Service Station.
Jeep CJ2A Specifications on The CJ2A Page Engine "Go-Devil" L-Head Number of cylinders........................................4 Bore...............................................................3 1/8" Stroke............................................................4 3/8" Piston Displacement........................................134.2 cu. in. Compression Ratio..........................................6.48 to 1 Horsepower -- SAE........................................15.6 Horsepower (actual @ 4,000 RPM)..
Above 90º F.................SAE 30 Not Lower than 32º F...SAE 20 or 30 As Low as +10º F........SAE 20 W As Low as -10º F.........SAE 10 W To temperatures below -10º F, use SAE 10 W plus 10% kerosene Valve and Ignition Timing Inlet opens 9 degrees before top centre Inlet closes 50 degrees after bottom centre Exhaust opens 47 degrees before bottom centre Exhaust closes 12 degrees after top centre Spark Setting Piston Measurements From Top Centre .039" (9.91 mm.) 3.772" (95.81 mm.) 3.799" (96.49 mm.) .
CJ2A Operation and Care Manual -- Inspections and Precautions At assembly a restrictor is placed between the intake manifold and the carburetor to limit the road speed to approximately 42 mph. To protect the vehicle, leave the restrictor in position for the first 500 miles of road operation, or equivalent in industrial operation, after which remove and discard it. It is an obligation of the Selling Dealer to carefully inspect and adjust your Universal Jeep before delivery.
CJ2A Operation and Care Manual -- Getting Started FIG. 1 - VEHICLE CONTROLS 1. Windshield Wiper Arm 2. Windshield Wiper Blade 3. Windshield Centre Lock 4. Windshield Glass 5. Hand Wiper Handle and Knob 6. Windshield Tubular Frame 7. Windshield Frame and Glass Assembly 8. Windshield Inner Adjusting Arm 9. Windshield Outer Adjusting Arm 10. Adjusting Wing Screw 11. Top Bow Storage Retainer 12. Instrument Panel Light 13. Choke Control 14. Windshield Clamp 15. Ammeter 16. Hand Brake Handle 17.
FIG. 2 -- SIDE SECTIONAL VIEW OF ENGINE 1. Fan Assembly 2. Water Pump Bearing and Shaft Assembly 3. Water Pump Seal Washer 4. Water Pump Seal Assembly 5. Water Pump Impeller 6. Piston 7. Wrist Pin 8. Thermostat Assembly 9. Water Outlet Elbow 10. Thermostat Retainer 11. Exhaust Valve 12. Intake Valve 13. Cylinder Head 14. Exhaust Manifold Assembly 15. Valve Spring 16. Valve Tappet Self-Locking Adjusting Screw 17. Engine Plate -- Rear 18. Camshaft 19. Flywheel Ring Gear 20. Crankshaft Packing -- Rear End 21.
• Shift the lever into the reverse position, slowly release the clutch pedal and regulate the car speed with the foot accelerator. TO USE THE ENGINE AS A BRAKE. The most effective brake for holding the vehicle back on a steep grade is the engine. To use the engine as a brake, shift into one of the lower speeds before starting to descend. Keep the clutch engaged, the throttle closed, and the ignition “ON”. Low gear will hold any vehicle effectively on any hill it can climb.
STEERING KNUCKLE OIL SEAL. When parking during cold, wet weather, swing the front wheels from right to left to wipe away moisture adhering to the front axle universal joint housings and oil seals, Fig. 5. This will prevent freezing with resulting damage to the oil seal felts. When the vehicle is stored for any period, the front axle universal joint housings should be coated with light grease to prevent rusting. How to Save Gasoline 1.
CJ2A Operation and Care Manual -- General Lubrication General Lubrication The use of high grade lubricants and regular application is specially essential when operating the “Jeep” because of the diversified service it performs. The amount of trouble free service received will be in proportion to the care given. Lubricate the vehicle in accordance with the type of service performed.
of industrial or field use. Drain the filter at each oil change to prevent the old oil contained in the filter from mixing with and contaminating the new oil. Replace the element at each 8000 miles of highway use or 200 hours of industrial or field use. AIR CLEANER. Care of the air cleaner is EXTREMELY IMPORTANT – especially when the vehicle is used under dusty conditions. Clean and refill the air cleaner reservoir to the level mark, with oil of the same grade used in the engine, at etch engine oil change.
CJ2A Operation and Care Manual -- Proper Maintenance NEVER RUN ENGINE IN CLOSED GARAGE Due to the presence of carbon monoxide (a poisonous gas in the exhaust of the engine) never rub the engine for any length of time while the vehicle is in a small closed garage. Opening the doors and windows will lessen the danger considerably, but it is safest if adjustments are being made that require the operation of the engine, to run the vehicle out-of-doors. INSPECTION.
1. Condenser 2. Lubricating Wick 3. Breaker Arm Pivot 4. Breaker Cam 5. Distributor Points 6. Oiler 7. Adjustment Lock Screw 8. Adjusting Screw The breaker points should be cleaned and adjusted to .020" (0.51 mm.) opening. Remove all of the spark plugs except No. 1. Rotate the crankshaft until No. 1 piston is coming up on the compression stroke which can be determined by the resistance in the cylinder.
CJ2A Operation and Care Manual -- Proper Maintenance (part 2 -- Engine Fails to Start, Oil System) ENGINE FAILS TO START Should the engine suddenly stop or fail to start, check the cause as follows. Also see Emergency Chart. • Make sure there is gasoline getting to the carburetor (Note: Should the trouble be traced to the gasoline supply see FUEL SYSTEM) and that the ignition switch is “ON”. • Check ignition circuit wiring connections to be sure they are tight and clean.
ENGINE MOUNTINGS The rubber engine mountings, which are attached to the frame side rail brackets and to the support plate, prevent fore-and-aft motion of the engine, yet allow free sidewise and vertical oscillation which neutralizes vibration at the source. Keep the mountings tight. A loose engine may cause vibration, clutch chatter or high fuel level in the carburetor. The rubber surface of the mountings partially insulates the engine from the frame.
FLOATING OIL INTAKE The floating oil intake (No. 28, Fig. 2) is attached to the crankcase with two screws. The construction of the float and screen cause it to remain on top of the oil, preventing the circulation of water and dirt. Once each year remove the float, screen and tube and clean thoroughly with a suitable cleaning fluid. When replacing, place some sealer on the gasket where the tube bears against the engine crankcase.
CJ2A Operation and Care Manual -- Proper Maintenance (part 3 -- Engine Electricals, Fuel and Cooling Systems.) GENERATOR The generator is a 35-ampere, two-brush unit which does not require adjustment to increase or decrease output. This is accomplished by the regulator which limits the current generated to that which is required by the battery. The generator charging rate, as shown by the ammeter, will be low when the battery is well charged and correspondingly higher as charging is required.
FUEL SYSTEM The fuel system consists of the fuel tank lines, fuel pump, carburetor and air cleaner. The most important maintenance attention is to keep the system clean and free of water, also periodically inspect for leaks. Should the vehicle be stored for an extended period, the fuel system should be completely drained and the engine started and allowed to run until the carburetor is emptied. This will avoid oxidation of the fuel, resulting in the formation of gum in the units of the system.
camshaft, Fig. 13. The pump draws gasoline from the fuel tank, through a filtering screen mounted in the pump sediment chamber and forces it to the carburetor. The pump pressure is 4 ½ lbs. at 16” above the outlet at 1800 rpm. Engine speed. The sediment chamber can be removed by backing off the thumbscrew nut sufficiently to permit swinging the wire clamp to one side. The bowl or cover should be washed and wiped dry and the screen dried and then cleaned with a stiff brush.
WATER PUMP The water pump assembly Fig. 15 is a centrifugal impeller type, of large capacity to circulate the water in the entire cooling system. The sealed type double-row ball bearing is integral with the shaft and is packed at the time of assembly with a special high melting point grease, so requires no lubrication. FAN BELT The fan and generator are driven by a “V”-type belt.
CJ2A Operation and Care Manual -- Proper Maintenance (part 4 -- Electrical System) ELECTRICAL SYSTEM The wiring diagram (Fig. 16) shows the general arrangement of all of the electrical circuits, together with all the units in correct relation to the position in which they are found. Regular inspection of all electrical connections avoids failures in the electrical system. When tracing any one particular circuit, note that the wires have different coloured tracers to identify each individual wire.
Should it be necessary to install a new light switch, refer to the wiring diagram, which indicates the correct wires to install on the several terminals. To remove the switch, loosen the set screw in the side of the switch control knob and remove the knob by unscrewing. The retaining nut may then be removed and the switch removed through the rear of the instrument panel. STOPLIGHT SWITCH The stoplight switch is of the diaphragm type and is located in the front end of the brake master cylinder.
CJ2A Operation and Care Manual -- Proper Maintenance (part 5 -- Transmission and Axles) CLUTCH The clutch is of the single, dry plate type consisting of a pressure plate assembly, having three pressure springs, three release levers; and a spring cushioned, faced driving plate mounted on a hardened steel, splined hub. Clutch release is accomplished by moving the release bearing toward the flywheel.
Poppet balls and springs retain the gears in mesh and an interlock prevents shifting into two gears at one time. Should any trouble be experienced with the transmission assembly, consult your Willys-Overland Dealer. TRANSFER CASE ASSEMBLY The transfer case Fig. 23 is an auxiliary unit located at the rear of the transmission. It is essentially a two speed transmission, which provides a low and direct gear, also a means of connecting the drive to the front axle.
1. Cap, Wheel Hub -- Left or Right 2. Cap Screw 3. Shim Pack, Adjusting, Front Axle Universal Joint 4. Cone and Rollers, Wheel Bearings 5. Spindle, Front Wheel 6. Brake Drum 7. Brake Cylinder Assembly -- Front 8. Plate, Backing, Front and Rear Brake Assembly 9. Cup, King Pin Bearing 10. Nut 11. Pin, King 12. Cone and Rollers, King Pin Bearings 1. Hypoid Bevel Drive Gear and Pinion Set (Matched) 2. Drive Pinion Oil Seal 3. Universal Joint End Yoke Assembly 4. Drive Pinion Nut 5.
1. Wheel Hub Cap, Left or Right 2. Axle Shaft Nut 3. Wheel Hub 4. Brake Drum 5. Brake Cylinder Assembly, Rear 6. Backing Plate, Front and Rear Brake Assembly 7. Brake Cylinder Bleeder Screw 8. Brake Hose Connection 9. Axle Shaft Grease Retainer, Outer 10. Cone and Rollers, Axle Shaft Bearing 11. Axle Shaft, Left 12. Differential Bearing, Cone and Roller 13. Differential Bearing Adjusting Shims 14. Hypoid Bevel Drive Gear and Pinion Set (Matched) 15. Pinion Bearing Positioning Shims 16.
CJ2A Operation and Care Manual -- Proper Maintenance (part 6 -- Brakes) BRAKES The foot or service brakes are hydraulically actuated in all four wheels. The brakes are of the two-shoe, double anchor type and have chrome-nickle alloy iron drums. The hand brake is mechanically operated through a cable and conduit to an internal expanding type brake mounted on the propeller shaft at the rear of the transfer case.
CJ2A Operation and Care Manual -- Proper Maintenance (part 7 -- Steering and Suspension) 1. Tie Rod - Right 2. Tie Rod Socket - Right 3. Knuckle and Arm - Right 4. Steering Bell Crank 5. Steering Connecting Rod 6. Steering Gear Arm 7. Steering Gear Arm Assembly 8. Knuckle and Arm - Left 9. Tie Rod Socket - Left 10. Tie Rod - Left 11. Socket Assembly 12. Steering Bell Crank Pin 13. Steering Bell Crank Cotter Pin 14. Steering Bell Crank Shaft STEERING SYSTEM The “Steering System” is illustrated in Fig. 30.
shims, Fig. 32, No. 2 to adjust the bearing with .001" to .003" end float which will be just perceptible when tested by hand. The shims available for this adjustment are .003" - .005" and .030" thick. Examine the grease retainer to be sure it is serviceable -- replace it if in doubt, and reassemble. MAINTENANCE OF WHEEL BEARINGS When the vehicle is used for road work, lubricate and adjust the front wheel bearings once each year; if used in dusty field work, twice each year.
of the spring. Hold the "U" shackle tightly against the frame bracket and start the upper bushing on the shackle, care being taken when it enters the thread in the frame, that it is not cross-threaded.
CJ2A Operation and Care Manual -- Emergency Chart) No adjustment should be made, or any parts tampered with, until the cause of the trouble is ascertained, otherwise adjustments which are properly made may be destroyed. The trouble should be analyzed first. STARTING MOTOR WILL NOT TURN ENGINE • Battery weak. • Battery connection dirty or loose. • Battery or engine ground wire connections loose. • Battery to starting motor wire connections loose at starting motor end. • Starter switch contacts dirty.
• • • Improper valve timing. Clutch slipping. Exhaust pipe or muffler obstructed. LACK OF COMPRESSION • Faulty cylinder head gasket. • Insufficient tappet clearance. • One or more improperly fitted pistons or piston rings. • Valves not seating properly. POPPING BACK THROUGH THE CARBURETOR (This usually indicates a too lean mixture.) • Dirt in carburetor. (Fuel pump strainer dirty, see FUEL SYSTEM.) • Water in fuel. • Air leak at intake manifold connections. • Incorrect ignition timing.
CJ2A Operation and Care Manual -- Extra Equipment) Much of the utility of the Jeep is due to the extra equipment which has been designed to adapt it for farming and diversified occupations and industries. The maintenance and use of this equipment is outlined in the following paragraphs. GOVERNOR (KING SEELY) The governor is a centrifugal type unit which gives precision control of engine speeds. When speed control is not desired it should be disengaged with the twin-pin type clutch No. 1, Fig. 33.
required or provided with this governor, however this slack or lost motion is provided to cushion any slight irregularities in governor control. MAINTENANCE Change the oil in the governor at each engine oil change, using the same grade oil used in the engine. Fill it to the level plug opening slowly – do not overfill. Should any trouble occur which requires disassembly, consult your Willys-Overland Dealer.
The other gear may be removed in the same manner after removing cover plate. Interchange the gears and reassemble in reverse order with the long side of the gear hub toward the cover opening. Use care that the shims are replaced in the same position relative to the bearings from which they were removed. Do not overlook refilling the housing with lubricant. The speed of the output shaft in relation to the vehicle ground speed is important.
Also select the correct upper side rail (a rod approximately 30” long with one end curved) which will assemble with the curved end next to the windshield with the curve extending up and out and with the welded eye extending in. After selecting the correct parts install the clamp bracket, with the stud extending in and place the eye in the curved end of the side rail over the stud on the inside of the clamp bracket.
CJ2A Operation and Care Manual -- Plowing Method, PTO and Vehicle Speeds) To avoid loss of time and minimize turning at the headlands while plowing a field, the following procedure is recommended: Lay out the field lengthwise in convenient lands or sections as shown by the back furrows in Fig. 38. The width of the lands will vary according to the field size; however, make the lands as near ten rods in width as possible.
High Low 7 High Low 8 High Low 9 High 595 655 655 714 714 774 774 10.81 4.89 11.89 5.34 12.97 5.78 14.05 1074 1182 1182 1289 1289 1396 1396 19.51 8.83 21.46 9.63 23.41 10.43 25.36 1666 1833 1833 2000 2000 2166 2166 30.25 13.70 33.27 14.94 36.31 16.19 39.33 857 942 942 1028 1028 1114 1114 10.81 4.89 11.89 5.34 12.97 5.78 14.05 1547 1702 1702 1856 1856 2011 2011 19.51 8.83 21.46 9.63 23.41 10.43 25.36 Pulley Speeds (R.P.M.) -- 8" Pulley. Power Take Off Gear Ratios.
CJ2A Operation and Care Manual -- Directions for Ordering Parts) When new parts are necessary, it is recommended that these be ordered from the nearest Willys-Overland Dealer. Do not order parts in a letter in which some other subject is treated. When ordering parts for a particular vehicle, give the model, engine, and serial number of the vehicle.
CJ2A Operation and Care Manual -- Lubrication Chart FIG. 17 -- CHASSIS, SHOWING PARTS REQUIRING LUBRICATION Chassis Bearings, Nos. 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 Clean and lubricate each 1000 of road service. Make certain each bearing surface is properly lubricated and oil all clevis pins, yokes, hood hooks and the upper end of the hand brake conduit.
