Jeep UNIVERSAL CJ-3A User manual

LockYour Car
YourJeepisequippedwithanIgnition
Locktoprotectitagainsttheft.
Lockingisa partofparking. Theigni-
tionswitchisoperatedbya keywhich
shouldberemovedafterturningoff
theignition.
CAUTION:Everyownershouldrecord
thenumber oftheignitionlockkeyso
thatincasethekeysare lostothersmay
beobtainedbynumber. See Page6.
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Willys-Overland
OWNER’SMANUAL
UniversalJeep
ModelCJ-3A
FIRSTEDITION
Copyright1948
Willys-Overland Motors
Willys-Overland ExportCorporation
Toledo, Ohio, U.S. A
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Foreword
IN YOURpossessionisamotorvehiclethathasbeenthoroughlytestedandinspected.Likeanyotherpieceofmachinery, to
maintainitinfirstclasscondition, youshouldlubricateit atthetimeprescribedwiththepropergradeofoilandgreaseandkeep
all workingpartsandoilholescleanandfreefromdirtandgrit.Youshouldalsoperiodicallyhaveitsystematicallyinspectedat
anAuthorizedWillys-OverlandServiceStation.
Inthefollowingpageswehavesetforththeknowledgeeveryownershouldhaveofhisvehicle,that hemayknowhowtotake
thebestcareofitandhandleitinsuchawaythathewillgetmaximum service. Informationisalsomadeavailablecovering
externaladjustmentsandminoremergencyrepairs. Readand follow theseinstructionscarefully;wearesurethatyouwillthen
enjoythesatisfactoryoperationthat yourightfullyanticipate.
Shouldadjustment orrepairseemnecessarybeyond yourability, don’texperiment;havetheworkdonebyacompetentrepair
man.It willalwaysprovebestandcheapestin the end tohavetheworkdonebytheDealerfromwhomyoupurchasedyourcar.
ManyWillys-OverlandDealershavefactorytrainedmechanicsandallarefamiliarwiththeconstructionandadjustmentsthrough
thecooperationoftheManufacturer.
Donot attemptanyadjustmentsaslongasthevehicleisoperatingsatisfactorily.
BesuretoobtaintheOwnerServicePolicy, providedbyyourDealerondeliveryofyournewvehicle.
Caution
AcceptanduseonlyGenuineFactoryParts
Imitationpartsareusuallyofinferiorqualityandcandoseriousdamagetoothermechanicalpartsofyourvehicle.
GenuinepartsaresoldbyallauthorizedWillys-OverlandDealers. Besurenoneotherthangenuinepartsareplacedinyour
vehicle.
PresenceofpartsotherthanthosefurnishedbyWillys-Overland willvoidthemanufacturer’sWarranty.
NOTE:PartsreplacedunderthetermsoftheWarranty(Page4)mustbeleftwiththeWillys-OverlandDealerwhomakesthe
replacement, iffull credit isexpected.
Thisisimportant forOwnerstoknow, whentravelingoutsidetheterritoryinwhichtheirvehiclewasoriginallypurchased,
particularlywhencredit foroldpartscannotbeestablishedtothesatisfactionoftheDealer.
Inthisconnection,aforwardingaddressshouldbegivenbytheOwnerinordertoinsurethecredit reachinghim.
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Standard Warranty
HEonlyWarrantyunderwhichnewWillys-OverlandMotorVehiclesaresoldisthatoftheManufacturer,beingthe
StandardWarrantyrecommendedbytheAutomobileManufacturer’sAssociation,andisasfollows:
“Thisistocertifythatwe, WILLYS-OVERLAND MOTORS, INC.,TOLEDO, OHIO, U.S.A. warranteachnewmotor
vehiclemanufacturedbyus, tobefreefromdefectsinmaterialandworkmanshipundernormal useandservice, our
obligation underthisWarrantybeinglimitedtomakinggoodatourfactoryanypartorpartsthereof,includingallequipment
ortradeaccessories(excepttires)suppliedbytheCarManufacturer,whichshall, withinninety(90)daysaftermaking
deliveryofsuchvehicletotheoriginalpurchaserorbeforesuchvehiclehasbeendriven4000miles(6400Km.),whichever
eventshall first occur,bereturnedtouswithtransportation chargesprepaid,andwhichourexaminationshall disclosetoour
satisfactiontohavebeenthusdefective; thiswarrantybeingexpresslyinlieuofall otherwarrantiesexpressedorimpliedand
ofallotherobligationsorliabilitiesonourpart,andweneitherassumenorauthorizeanyotherpersontoassumeforusany
otherliabilityinconnectionwiththesaleofourvehicles.Thiswarrantyshallnotapplytoanyvehiclewhichshallhavebeen
repairedoralteredoutsideofanAuthorizedWillys-Overland Service Stationinanywaysoas,inthejudgmentofthe
Manufacturer,toaffectitsstabilityorreliability, norwhichhasbeensubjecttomisuse,negligenceoraccident.”
TheManufacturermakesnowarrantyagainst,norassumesanyliabilityforanydefect inmetal orothermaterialinanypart,
deviceortradeaccessorywhichcannotbediscoveredbyordinaryfactoryinspection.
WILLYS-OVERLAND MOTORS, INC.
NOTE—Willys-OverlandMotors, Inc., reservestherightat anytimeortimestorevise,modify, discontinueorchangeany
modelsofitsvehicles, oranypartorpartsthereof, withoutnotice; and,withoutit ortheSeller,incurringanyliabilityor
obligation tothePurchaser.
T
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GeneralData
Engine—ModelCJ-3A
NumberofCylinders4
Bore3-1/8”79.37mm.
Stroke4-3/8"111.12mm
PistonDisplacement134.2cu.in.2199.53cc
CompressionRatio6.48to1
HorsepowerSAE15.6
HorsepowerActual60
Revolutionsperminute4000
Torque~MaximumLbs.Ft10514.5kg.m
Revolutionsperminute2000
Wheelbase80”203.2cm.
Tread48-1/4”122.55cm
Overall Width68-25/32”174.703cm
Overall Height—Topup69-7/32”175.81cm
—Topdown53-1/2"135.89cm
Overall Length126-25/32”322.023cm
RoadClearance8-3/32"20.556cm
*WeightMaximum PayLoad800 lbs.362.88kg
Shipping(Lesswater,oilandfuel)2110lbs.955.83kg
Curb(Includingwater,oilandfuel)2203lbs.997.95kg
Gross (Loaded)3500lbs.1585.50kg
*If equippedwithaluminumfullenclosureadd55lbs.. (24.95kg.)—if
aluminumcabonlyadd40lbs.(18.14kg.).
MaximumApprovedDrawBarPull
(ContinuousOperation)1200lbs.544.32kg
FuelTankCapacity10.5gals.39.74liters
CoolingSystemCapacity11 qts.10.41liters
LAMPBULBS
HeadLamp(7in. SealedBeamType)
UpperBeam45 watts
LowerBeam35 watts
ParkingLampBulb3CP-SC--No. 63
TailandStop LampBulb21-3CP-DC—No. 1158
Instrument LampBulb2CP-SC---No. 55.
Fuse(ThermalType)-—OnLightSwitch30 Amperes
LocationofSerialNumber:Plateonrightsideofdashunderhood.
LocationofEngineNumber:Stampedonwaterpumpboss.
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Inspection
YourJeepwascarefullylubricatedand inspectedatthefactoryandagainthoroughlyservicedbytheSellingDealer.
Afteryourvehiclehasbeenoperated1000miles(1600 Km.)andalso2000 miles(3200Km.),return ittoyour
Dealerforthefree inspectionsinaccordance withFactoryService Policy. Theseinspectionsarefree withthe
exceptionof engineoiland anti-freezesolutionused.
Free Inspection
1000 Mile(1600Km.)
2000 Mile(3200Km.)
Checksteeringsystemand frontwheelalignment.
Checkspringclipnutsand springshackles.
Checkrearaxleforoiland leaks.
Adjustbodybolts.
Testservice andhandbrakes—Inflatetires.
Checkcoolingsystemforleaksandanti-freezeandfanbeltadjustment.
Adjustclutchpedal.
Checkoperationof transmissionandtransfercase—Checkforoil levelandleaks.
Checkbattery, generatoroutput, headlampsandhorn.
Tightenuniversaljointcompanionflangebolts.
Checkoperationof ammeter, heatindicator,fueland oilgauges.
Tightencylinderheadnuts—Checktimingand distributorpoints.
Setsparkplugs—Adjustcarburetor—Checkthrottlecontrols.
Checkengineforoil leaks—Checkfuellineconnections.
Adjustvalvetappets,ifrequired.
Changeengineoil (chargeforoil)—Lubricatevehicle.
Cleanandrefill, aircleaner.
Cleanfuelpumpsumpandstrainer.
Checkextraequipmentattaching screws—Checkforoil levelandleaks.
FILL INFORYOURREFERENCE
VehicleSerialNumber
EngineSerialNumber
PurchaseDate
IgnitionKeyNumber
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SPECIALPRECAUTIONS
Thereareseveralpointsof difference betweentheUniversalJeepand aconventionalvehicletoreceiveattention.As
ageneralprecautionand foryourinformationwearelistingthese“cautions”below:
TheJeepisequippedwithatransfercaseand four-wheeldrivetoprovideadditionaltractionandalowergearratio
foruseondifficult terrain.Usethefrontwheeldriveonlywhennecessary. Considerthefrontwheeldriveand the
transfercaseasalowergearratiothanthestandard transmissionlowgearanduseitonlywhengreaterpoweris
required.
Theuseof four-wheeldriveonhardsurfacedhighwayswill resultinrapidtirewearandhard shiftingof thetransfer
case, particularlywhenthefrontwheelsaresteeredevenataslightanglefromthestraightaheadposition. Ifhard
shifting occurs,disengagetheclutch,startengine,shifttransmissionintoreversegear,backvehicleafewfeet,and
disengageclutch.Iftransfercaseisinlowrange, shiftintohighthenshiftfrontaxledriveinto“out” position(lever
forward).
Twodraincocksareprovidedtodrainthecoolingsystem. Adraincockislocatedundertheleftsideof theradiator,
however,itisnecessarytodrainthecylinderblockseparately. Thecylinderblockdrainislocatedattherightfront
cornerof theblockdirectlyunderthegenerator. Loosentheradiatorfillercaptobreakthesealandpermitcomplete
draining.
Checkthelevelof thelubricantofteninthetransmissionandtransfercase.Besurethelubricantisatfillerlevelin
bothunitsatalltimes.
As astandard,theclutchpedalisadjustedwith 114”(31.75 mm.)free travel.As theclutchwearsthisbecomesless.
Besurethatthereisfree travelatalltimestopreventcontinuousoperationof theclutchreleasebearingand rapid
wearandslippageof theclutch.Thisadjustmentismadebylengtheningorshorteningtheclutchcontrolcable.
Theventilatorvalve, mountedintheintakemanifold,mustbefree tooperate.Ifitisstuckopenveryunevenengine
operationatlowspeedwill result.
Besuretheexhaustmanifoldheatcontrolvalveisfree atalltimesandthethermostaticcontrolspringisabovethe
stop.
Sixscrewsareusedtoattachthefrontwheelbrakebackingplateandspindletothespindlehousing.Thesescrews
arestandard indimensionsandthreadpitch, however,theyaremadeof special steeland receivespecial heat
treatment.Safetydemandsthatonlygenuinefactoryscrewsbeusedatthispoint.
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Proper Operation
DRIVINGANEW“JEEP”
Donotrunyour“UniversalJeep”fasterthan40milesanhour(64 Km./h.)forthefirst500 miles(800Km.)orif usedon
thefarmorforindustrialoperation,usecarewhenpullingheavyloadsinthelowergearratios.If the vehicleisoperatedat
highspeedswhileneworusedforheavypullingforalongperiod, thecloselyfittedpartsmightpossiblybecome
overheated,resultinginscoredpistons,cylinders orburnedbearings.Duringitsentirelife,neverracetheenginewhile
makingadjustmentsorwhenthevehicleisstandingidle.Ifthevehicleisnotproperlylubricated,ourWarrantyisnulland
void.BesuretohaveyourWillys-OverlandDealerinspectyourvehicleattheendof1000miles(1600Km.)orequivalent
usageandagainat 2000miles(3200 Km.).
TOMAKEVEHICLEREADY.
Fill theradiatorwithclean,soft water.Putgasolineinthetank.
Fill theoilreservoirthroughthefillerpipeatrightsideofengineuntil theoilindicatorstickregisters“FULL”. (See
“LubricationChart”,Page36).Supplyallpartsrequiringlubricationwithoilorlubricant.
See thatthetireshaveproperpressure(SeeTirePressure,Page51).
Adjusttherearviewmirrortocorrectpositionfordriver.Ifadequateviewisnot obtainable, themirrormaybeadjustedby
looseningthescrewthroughthemountingbracketorbytiltingintheballandsocket connection.
CONTROLSANDSWITCHES
Thepositionofall controlsandswitchesisshowninFig.1.
Thehornisoperatedbypressingthebuttonlocatedatthetopcenterofthesteeringwheel.
ThemainlightswitchNo. 27controllingalllightsisconvenientlylocatedontheinstrumentpaneltotheleft ofthesteering
post.It isoftheplungertype—pull allthewayout forthe“full on”position,half-wayfor“parking”andallthewayinisthe
“off”position.
Inadditiontothemainlightswitch,thehighandlowbeamsoftheheadlampsarecontrolledbyaselectorfoot switch,located
onthetoeboardtotheleftoftheclutchpedal. Pressingandreleasingtheswitchbutton,withthefoot, alternatelychangesthe
beamfromhightolowand vice versa.
TOSTARTENGINE
Putthetransmissiongearshift leverNo. 12,Fig. 1inneutral. PlacethetransfercaselowandhighshiftleverNo. 17indirect
gearorintherearpositionand disengagethefrontaxledrivebyplacingtheshiftleverNo.16intheforwardposition.
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PullthechokecontrolbuttonNo.8one-fourthofthewayout whichalsoopensthethrottleslightly.
PlacethekeyinignitionlockNo. 29andturnittotheright,closingtheignitioncircuit.
Disengagetheclutchbydepressingthepedal. Depressthefoot startingswitchNo.15.
Shouldtheenginefail tostartatonce, pullthechokeallthewayout andpressthestartingswitch.Whentheengine
starts,pushthechokeinaboutone-thirdoftheway. Setthechokecontrolatthebest operatingpositionandasthe
enginewarmsup,pushthechokeall thewayin.Donotrunwiththechokeoutasfueliswastedandtheengine
fouled.
Shouldtheenginefail tostart, seethe“EmergencyChart”,Page54.
1—HornButton16—FrontAxleDriveShiftLever
2—SteeringWheel17—UnderdriveShift Lever
3—WindshieldWiperMotor.Left18—AcceleratorFoot Rest
3A—WindshieldWiperMotor,Right (ExtraEquipment)19—BrakeMasterCylinderInspectionPlate
4—WindshieldWiperArms20—AcceleratorPedal
5—WindshieldWiperBlade21—BrakePedal
6—Ventilator22—ClutchPedal
7—InstrumentPanel Light8—chokecontrol23—Headlight DimmerSwitch
9—Ammeter24—-Heat IndicatorGauge
10—WindshieldClamp25—Speedometer
11—Hand BrakeHandle26—Oil Gauge
12-—TransmissionShiftLever27—MainLight Switch
13—HeaterSwitch28—Fuel Gauge
14—Heater(ExtraEquipment)29—IgnitionSwitch
15—StarterControlSwitch30—Tell-TaleLight
31—Hand Throttle
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FIG. 2SIDESECTIONALVIEWOFENGINE
1—FanAssembly2—WaterPumpBearingandShaft Assembly
3—WaterPumpSealWasher4—WaterPumpSeal Assembly
5—WaterPumpImpeller6—Piston
7—WristPin8—ThermostatAssembly
9—WaterOutletElbow10—ThermostatRetainer
11—ExhaustValve12—IntakeValve
13—CylinderHead14—ExhaustManifoldAssembly
15—ValveSpring16—ValveTappetSelf-LockingAdjustingScrew
17—EnginePlate—Rear18—Camshaft
19—Flywheel RingGear20—CrankshaftPacking—RearEnd
21—Oil Pan22—Crankshaft BearingRearLower
23—ValveTappet24—Crankshaft
25—Oil PumpandDistributorDtivcGear26—ConnectingRodCapBolt
27—Oil FloatSupport28—Oil FloatAssembly
29—Crankshaft BearingCenter—Lower30—ConnectingRodAssembly—No.2
31—ConnectingRodBolt Nut32—Crankshaft BearingFrontLower
33—Crankshaft Oil Passages34—Crankshaft ThrustWasher
35—Crankshaft Gear36—Crankshaft GearSpacer
37—TimingGearCoverAssembly38—FanandGeneratorDriveBelt
39—Crankshaft Oil Seal40—Crankshaft Nut
41—Crankshaft GearKey42—FanandGovernorDrivePulleyKey
43—TimingGearOil Jet44—Fan. GeneratorandGovernorDrivePulley
45—CamshaftThrustPlate46—CamshaftGearRetainingWasher
47—CamshaftGearRetainingScrew48—CamshaftGearThrustPlateRetainingScrew
49—CamshaftGear
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TOSTARTVEHICLE.
Releasehandbrake,ifset.Depressclutchpedal. Movetransmissiongearshiftlevertofirstspeedposition—seeFig.3.(Note
thatthefrontaxleandtransfercaseshiftleversarenotusedwhenthevehicleisdrivenon thehighwayinrearwheeldrive.)
Depressthefoot acceleratorpedalgraduallyand atthesametime,slowlyreleasetheclutchpedal.Allowthevehicletogain
momentum(twoorthreevehiclelengths),thenreleasetheacceleratoranddepresstheclutchpedalatthesamemoment.
Movetheshift leverpromptlytothesecond speedposition. Depress thefoot acceleratorpedalgraduallyand atthesametime,
slowlyreleasetheclutchpedal.
Shifttothirdor“high”speedinthesamewayatapproximately18 to20mph (29-32 Km./h.),releasingtheacceleratorand
depressingclutchpedalbeforemovingtheshiftlever.
Thesynchronizingmechanism inthetransmissionmakesgearshiftingsilentandeasy. Thisdeviceadjuststhespeedsofthe
twogearstobeengagedandprevents“clashing”.
TOCHANGETOLOWERSPEED.
Depresstheclutchpedal.
Movegearshiftleverquicklyinnext lowerspeed,increasetheenginespeedslightly, iftravelingonlevelroadandreleasethe
clutchpedal.
It willbefound advisabletomakethischangewhentheengineisplacedunderheavypull,orwhendroppingdowntoavery
lowspeed,aswhentravelingupasteepgrade,insand orincongestedtraffic.
Neverattempttomakethechangewiththevehicletravelingatahighrateofspeed.
TOSTOPTHEVEHICLE.
Releasethefoot accelerator.
Depresstheclutchpedalandapplyfoot brake.
Whenstopped,movegearshiftleverintoneutral.
Setthehandbrakeandreleasetheclutchandbrakepedals.
TOREVERSEVEHICLE.
Withvehicleatastandstill,depresstheclutchpedal.
Shiftthegearleverintoreverseposition,slowlyreleasetheclutchpedaland regulatethecarspeedwiththefoot accelerator.
TOUSEENGINEASABRAKE.
Themosteffectivebrakeforholdingthevehiclebackonasteepgradeistheengine.Tousetheengineasabrake,shiftinto
oneofthelowerspeedsbeforestartingtodescend.Keeptheclutchengaged,thethrottleclosedandtheignition “ON”.Low
gearwillholdanyvehicleeffectivelyonanyhillit canclimb.
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FIG. 4—END SECTIONALVIEWOFENGINE
1—IgnitionCoil2—CylinderHeadGasket
3—Exhaust ValveGuide4—IntakeManifoldAssembly
5—ValveSpringCoverAssembly6—Heat ControlValve
7—CrankcaseVentilatorGasket8—ExhaustManifoldAssembly
9—CrankcaseVentilatorAssembly10—DistributorShaft FrictionSpring
11—Oil PumpDrivenGear12—Oil PumpGasket
13—Oil PumpAssembly14—Oil PumpPinion
15—Oil PumpCover16—Oil PumpReliefValve
I7—Oil PumpReliefPlungerSpring18—Oil PumpReliefPlungerShim
19—Oil PumpReliefPlungerSpringRetainer20—Oil PumpShaft
21—Oil PanAssembly22—Oil PanDrainPlug
23—Oil FloatSupport24—Crankshaft BearingDowel
25—Crankshaft BearingCaptoCrankcaseScrew26—Oil FloatAssembly
27—Oil FillerTube28—Oil FillerCapandLevelIndicator
29—DistributorOiler30—DistributorAssembly
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Neverengagetheclutchsuddenlywhenthevehicleiscoastingwithclutchreleasedandthetransmissiongearsinmesh,as
damagetothedrivingmechanismmayresult.
STARTING VEHICLEON UPGRADE.
Instartingonanupgrade,holdthevehiclewiththehandbrake,disengagetheclutchandshift thetransmissionintolowspeed,
thenacceleratetheenginewiththefoot acceleratorintheregularwaywhilesimultaneouslyreleasingthehandbrakeand
engagingtheclutch.
SHIFTING GEARINTRANSFERCASE.
Thetransfercaseisessentiallyatwospeedtransmission,whichprovidesalowandadirect gearandalsoameansof
connectingtheenginepowertothefrontaxle. Itisanauxiliaryunit attachedtotherearofthestandardtransmission.
Control ofthetransfercaseisthroughthetwoshiftlevers,Fig.1No.16andNo.17. Theleftlever,No. 16,isusedtoconnect
and disconnect thepowertothefrontaxle. Therightlever,No.17 isusedtoshiftthetransfercasegearstosecureeither
“High”(direct drive)oraverylowgearratioforheavypullingrequirements.
Instructionsforshiftinggearsinthetransfercaseandengagementofthefrontaxledriveareasfollows:See Fig. 3.
1.Toengagefrontaxledrive,depresstheclutchpedal, releaseacceleratorandmovethelefthand shiftlever(No. 16)torear
position.
2.Withthefrontaxledriveengaged,therighthandlever(No.17)maybeshiftedtotherearinto“High”(direct)orforwardinto
“Low”. The“Neutral”positionmidwaybetween“High”and“Low”isforusewhenthepowertake-off beltdriveisused.The
vehiclecannot bedrivenwhenthisleverisin“Neutral”.
3.Todisengagethefrontaxledrive,depresstheclutchpedal, releasetheacceleratorandshifttheleftlevertotheforward
position.Thetransfercasecanbeoperatedonlyin“High”(directdrive)whenthefrontaxledriveisdisengaged.
4.Shiftingfromhigh tolowtransfercasegearshouldnot beattemptedexceptwhenthevehicleispracticallyat astandstill.The
front axledrivemust beengagedforthisshift.Releasetheacceleratoranddepresstheclutchpedal—movethelefthandshift
levertotherearpositiontoengagethefrontwheeldrive, thenmovetherighthandshiftlevertoforwardposition (lowtransfer
casegear).
5.Shiftingfromlow tohightransfercasegearmaybeaccomplishedatanytime,regardlessofvehiclespeed. Releaseaccelerator
and depressclutchpedalandshiftrighthandleverintorearposition.
USEOFFOURWHEELDRIVE.
The“UniversalJeep”isequippedwithfour-wheeldriveandtransfercasetoprovideadditionaltraction andalowergearratio
foruseondifficultterrainandtoprovidelowspeedpullingpowerforindustrialandagriculturaluse.Four-wheeldriveshould
beusedonlywhengreatertractionandpowerarerequiredthanthatprovidedbythestandardtransmissionlowgear.
Tiremaintenanceisofutmostimportancewhenusingfour-wheeldrive.Slightdifference intheoverall diameterofthefront
and rearwheelswill result inhardshifting. Thisdifference maybecausedbyusingabadlyworntireononewheelandnew
tiresontheothersorbyoperatingthevehiclewithoneormoreofthetiresunderinflated.
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Balance tirewearbetweenthefrontandrearwheelsascloselyaspossible. Keeptiresinflatedtorecommended
pressure(Page51)especiallywhenoperating thevehiclewithmaximumload.
Avoidtheuseof four-wheeldriveonhard surfacedhighwaysasitwillresultinrapidtirewearand hardshifting
ofthetransfercasegears. Shouldhard shiftingoccur, disengagetheclutch, startengine, shiftthetransmission
intoreversegear,backthevehicleafewfeetanddisengagetheclutch.Iftransfercaseisinlowrange, shiftinto
high,thendisengagefrontaxledrive(leftleverforward).
STEERING KNUCKLEOILSEAL.
Whenparkingduringcold, wetweather, swingthefrontwheelsfromrighttolefttowipeawaymoistureadhering
tothefrontaxleuniversaljointhousingsandoil seals, Fig.5.Thiswillpreventfreezingwithresultingdamageto
theoil sealfelts.Whenthevehicleisstoredforanyperiod,thefrontaxleuniversaljointhousingsshouldbe
coatedwithlightgreasetopreventrusting.
FIG. 5—KNUCKLEOILSEAL
HowtoSaveGasoline
1.In coldweathereconomicalstartingof theengineiseasilyobtainedbypressingdownontheaccelerator
pedal once ortwice, thenpushdownontheclutchpedaland startengineusingthechokesparingly. Donotusethe
chokewhenstarting awarmengine.
2.Donotusethechokeexcessivelywhileengineiswarming upandneverleaveitoutlongerthanabsolutely
necessary.
3.Accelerategently. Trampingontheacceleratorpumpsmore• gasolineintothecylindersthancanbe
effectivelyused.
4.Holdingthecarinsecondgearuntilyougetup tohighspeedsmayeasilydoublethegasolineyoushould
useingetting underway. Shiftintohighgearatabout20milesperhour (32Km./h.).
5.Fastdrivingusesup moregasoline.Travelatmoderatespeedsifyouwantgasolineeconomy.
6.Deceleratetoagradualstop. Suddenstops,likesuddenstarts, arewastefulof gasoline.
7.Park yourcarintheshadeifpossible,hotsunevaporatesgasoline.
8.Don’tdriveyourtireswithless thantheproperairpressure. Under-inflatedtiresmeanmoreroadfriction,
moreworkfortheenginetodo—andthereforemoregasolineconsumed.See “TirePressure”Page51.
9.Keepthebatterychargedupingoodcondition. Ithelpsstartingandprovidesgoodignitionthereby
reducingloss of gasoline.
10.Lettingtheengineidleforlong periodswastesgasoline.
11.Besurethatthecarburetorisinproperconditionformaximummileageandpower.
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12.Onefaultyordirtysparkplugmaywasteasmuchas10 percent ofyourgasoline.Havethesparkplugstested
occasionally.
13.Keepyourcarwelllubricatedatalltimes,andbeverycarefultofollowtheinstructionson“Lubrication”.
14.Keeptheradiatorfilledtotheproperlevel, yourenginewillremainatamoreconstanttemperature.Anoverheated
engineusesmoregasoline.
15.Checktheoperationoftheautomaticheatcontrol ontheexhaust manifold. Thepurposeofthisheateristowarmthe
mixtureofairandgasolineasitleavesthecarburetor,inordertogivebettervaporization.(SeeManifoldHeat Control,Page23.)
16.It isagoodideatohaveacompleteenginetune-up every5,000miles(8000Km.),oratleasttwiceayear—intheFall
whenpreparingforWinterdrivingandagainintheSpring.TheOwnerServicePolicyentitlesyoutoanadjustmentandcomplete
inspection withoutchargeattheendofthefirst1000miles(1600Km.)andagainat2000 miles
(3200Km.).
GeneralLubrication
Theuseofhighgradelubricantsandregularapplicationisspeciallyessentialwhenoperatingthe“Jeep”becauseofthe
diversifiedserviceit performs.Theamountoftroublefreeservice receivedwill beinproportion tothecaregiven.Lubricate
thevehicleinaccordancewiththetypeofserviceperformed.
Thefollowingpagesshouldbereferredtoforinstructionscoveringgradeandquantityoflubricantrequiredforallpartsofthe
vehicle.Themileageinstructionsshouldbefollowedwhenthevehicleisusedforroadwork.Itisimpossibletogiveaccurate
hourlyinstructionsbecauseofthediversifiedserviceandconditionsunderwhichthevehiclemaybeoperated. Thehours
indicatedareapproximate.Toobtainmaximum service, goodjudgmentmustbeusedtolubricatethevehicleaccordingtothe
typeofworkbeingdone.Asanexample—whenusedasafarm tractorunderdustyconditionsthechassisshouldbelubricated
dailyasthenewlubricant forcesgritand.dirt, whichhasaccumulatedduringtheday, fromthebearingsurfaces.Underthese
conditions, theaircleanershouldalsobecleanedandrefilleddailyorunderextremeconditionstwicedaily.
Becauseoftheimportanceofcorrect lubrication,detailedrecommendations,unit capacitiesandspecificationsaregiveninthe
followingparagraphs.AlsorefertotheLubricationChartonPage36.
LubricationSpecifications
TypeWinterSummer
ChassisLubricationChassisGreaseNo.0No.1
Transmission andTransferCaseTransmission GearOilSAE80SAE90
Differentials—FrontandRearHypoidGearOil SAE90SAE90
SteeringGearSteeringGearLubricantSAE140 SAE140
WheelBearingsWheelBearingLubricantNo.2No.2
UniversalJoints (FrontAxleShaft)UniversalJointLubricantNo.0No.1
orChassisGreaseNo.0No.1
UniversalJoints (PropellerShaft)ChassisGreaseNo.0No.1
PowerTake-OffHousing... HypoidGearOil SAE80SAE80
AirCleaner. . .EngineOil SameGradeusedinengine
Governor. EngineOil SameGradeusedinengine
Engine. EngineOil See Below
Above90°FNotLowerthan32°F. As Lowas+10°F.AsLowas.~10°F.
32°C0°C. -12°C.-23°C.
SAE30 SAE20or30SAE20WSAE10W
Fortemperaturesbelow—10°F. (-23°C.)useSAE10 plus10%keroseneorSAE5W.
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LubricationCapacities
U. S.ImperialMetric
EngineCrankcase—oilfilterempty(qts.)54-1/24.73liters
Transmission
TransferCase(pts.)6-1/25-1/23.7liters
Differential—FrontAxle(pts.)2-1/221.18liters
Differential—RearAxle(pts.)2-3/42-1/41.30liters
OilBathAirCleaners (pts.)1-1/41591.40CC
BrakeSystemFluid(pts.)3/45/8354.84CC
PowerTake-Off(pts.)13/4.473liters
PulleyDriveUnit(pts)3/45/8354.84CC
ENGINELUBRICATION.
Lubricationoftheengineisaccomplishedbymeansofaforce-feedcontinuouscirculatingsystem. Thisiseffectedbymeans
ofarotortypepump, locatedexternallyontheleftsideoftheengine,anddrivenbyaspiral gearonthe.camshaft.
Theoilisdrawnintothecirculatingsystemthroughafloatingoilintake.Thefloatingintakedoesnotpermit waterordirtto
circulate, whichmayhaveaccumulatedinthebottomoftheoil pan,becausetheoilisdrawnhorizontallyfromnearthetop
surface.
Anoil pressuregaugeismountedintheinstrument panel, whichindicatesthepressurebeingsuppliedtothecirculating
system. Failureofthegaugetoregistermayindicateabsence ofoil,leakageorafault inthelubricationsystemand theengine
shouldbestoppedimmediately. Ifthereisplentyofoil inthereservoirthemechanical fault mustbecorrectedbeforestarting
theengine. Standardgaugereadingisapproximately30 to35lbs.(5.355 to6.247Kg./cm.)at30milesperhour(48Km./h.)
and 5to10(.892 to1.785Kg./em.)atidlespeed.
Thequantityofoil inthecrankcaseismeasuredbythebayonettypeoil levelindicatorwhichiscombinedwiththeoilfiller
caplocatedintheoil fillerpipeattherightsideoftheengine.Whentheoil levelisbelowthe“Full”mark,poursufficientnew
oil intothereservoirtobringthelevel tothe“Full”mark.
Whenthevehicleleavesthefactorythecrankcaseisfilledtothecorrectlevelwithoiloftheproperviscosityforthe“break-in”
period. Whenthevehicleisusedonthehighway, completelydraintheengineoil at500 miles(800Km.),and at1000miles
(1600Km.),thenevery2000 miles(3200Km.)thereafter,byremovingthedrainpluginthelowerleftsideoftheoil pan.
Replacethedrainplugandrefill with4qts.(3.8liters)(5qts. [4.7liters]whentheoilfilterhasbeendrained)offreshoil. For
heavyindustrialordustyfieldwork,changetheoilatthefirst10hours,and each50hoursthereafter.Tosecuremaximum
enginelife,watchtheconditionoftheoil closelyand shoulditbecomecontaminated,duetotheconditionsunderwhichthe
vehicleisbeingoperated,changeitimmediately.
Alwaysdraintheoil whentheengineiswarm. Thebenefitofdrainingis,toalargeextent,lostifthecrankcaseisdrained
whentheengineiscold,assomeoftheforeignmatterwillremaininthebottomoftheoilpan.
At leastonceayear,preferablyintheSpring,removetheoilpanandfloatingoilintakeandwashthoroughlywithcleaning
solution.
CHASSISLUBRICATION.
WhenlubricatingthechassisrefertotheLubricationChartonPage36.
Forhighwaytravel,cleanandlubricatepointsindicatedasNo.1each
1000miles(1600Km.). Whenusedinindustrialoragriculturalworkthe
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periodforlubricationdependsentirelyuponthetypeofworkbeingdone.Whendoingdustyfieldwork,lubricatethesepoints
dailyasgrit anddirtwillworkintothebearingsurfacesandcauserapidwearunlessforcedoutbynewlubricant.
Theimportanceofusingagoodgradeofchassislubricant cannotbeexaggerated,forthecost will bemorethanrepaidby
longerwearandgoodservice.
OILFILTER.
Theoil filtershouldbedismantled,cleanedandthefilterelementreplacedattheend ofthefirst2000miles(3200Km.)of
highwaytravel, or100hoursofindustrialorfielduse. Drainthefilterateachoilchangetoprevent theoldoilcontainedinthe
filterfrommixingwithandcontaminatingthenewoil. Replacetheelementateach8000miles(12,800 Km.)ofhighway
travel or200hoursofindustrialorfielduse.
AIRCLEANER.
CareoftheaircleanerisEXTREMELYIMPORTANT—especiallywhenthevehicleisusedunderdustyconditions.Clean
and refilltheaircleanerreservoirtothelevelmark, withoil ofthesamegradeusedintheengine,ateachengineoil change.
Whenthevehicleisusedforfieldwork,cleanandchangeoilinthecleanerDAILYandunderextremelydustyconditions
TWICEDAILY. Whencleaning,usealongscrewdriverorothersuitabletooltodislodgedirtstickingtothebottomandsides
oftheintakepassageinthebodyofthecleaner.
STEERING GEAR.
Checkthelevel ofthelubricant inthesteeringgearhousingevery1000 miles(1600Km.).Avoidtheuseofcup grease,
graphite, whiteleadorheavysolidifiedoil.Removethepluginthesteeringgearhousinganduseahandgun tofillthe
housingslowly.
WATERPUMP-CLUTCH.
Thewaterpumpbearingandclutchreleasebearingareprelubrieatedatassemblyand thelubricantlastsforthelifeofthe
bearings.
GENERATOR.
Twooilersareprovided,oneateachend; threetofivedropsofengineoil isrecommendedevery1000miles(1600 Km.).Be
suretoslipthecommutatorendholecoverbackinplace.
STARTING MOTOR.
Theoilholecoveronthecommutator(front)end slipstooneside;putthreetofivedropsofengineoilinthisholeevery1000
miles(1600Km.).Besuretoslipcoverbackinplace.
IGNITION DISTRIBUTOR
Theoileronthedistributorshouldbelubricatedevery1000 miles(1600Km.)withseveraldropsofengineoil,Fig. 7, No.6.
Alsoplaceonedropoflightengineoilonthewick,No.2locatedinthetopoftheshaft, whichisaccessiblebyremovingthe
rotorarmandsparinglyapplysoft greaseonthebreakerarmcamNo.4,andadropofoilonbreakerarm pivot,No. 3.
SPEEDOMETERAND DRIVE.
Removethedriveshaftfromthetubeonceeachyear,cleanitthoroughlyand lubricatewithagoodqualitylight graphite
grease.
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UNIVERSALJOINTS(PROPELLERSHAFT).
Every1000 miles(1600Km.)lubricatepropellershaftuniversaljointsandslipjointswithagoodquality
lubricant. Lubricatedailyforfieldwork.
UNIVERSALJOINTS(FRONTAXLESHAFT).
Thefrontaxleuniversaljointsareinclosedinthesteeringknucklehousingswhicharefilledwithlubricantso
requirenoattentionotherthancheckingeach1000miles(1600Km.)tobesurethehousingsarefilledtoplug
level.
Once eachyear(12,000miles)(19,200Km.)theaxleshaftsanduniversaljointassembliesshouldberemoved,
thoroughlycleanedandthehousingsfilledwithnewlubricant. Whenthevehicleisusedfordustyfieldwork,
cleanand repackthehousingstwice eachyear.
POWERTAKE-OFF PROPELLERSHAFTUNIVERSALJOINTS.
Foraverageservice theoriginalfactorylubricationwilllastthelifeofthevehicle.Ifthepowertake-offisused
oftenforcontinuousoperation,disassembleand repackonce eachyear.
WHEELBEARINGS.
Frontwheelbearingsshouldberemoved, thoroughlycleaned,checkedand repackedtwice yearlyorevery6,000
miles(9600Km.).
Therearwheelbearingsareequippedwithhydrauliclubricators.Lubricatethem sparinglytoguardagainst
surplusoilsaturating thebrakelining.Anoil reliefholeattopof housing,Fig. 32,No. 1,indicateswhenthe
bearingisfilledwithoil.
TRANSMISSION AND TRANSFERCASE.
Drilledpassagesareprovidedbetweenthetransmissionandtransfercasehousingsforcirculationof the
lubricating oiltoprovideunitlubricationof thetwoassemblies. Service eachassemblyindividually. Checkthe
oil leveleach1000miles(1600 Km.)orateachlubrication.Drainandrefill ateach6000miles(9600 Km.)or
300 hoursof fieldwork.
Note:Therequirementsofthesehousingsare smallforeconomy, therefore, it isveryimportantthatthelubricantbe
changedevery300 hourswhenthevehicleEsusedfordustyfieldwork.
FRONTAND REARDIFFERENTIALS.
Thedifferentialgearsrequireextremepressurelubricant,whichissuitableforhypoidgeartypeaxles. Thelevel
ofthelubricantintheseunitsshouldbecheckedevery1000 miles(1600Km.). Donotmixdifferenttypesof
hypoidlubricants.
Drainand refillthehousingseach6000 miles(9600Km.)ortwice yearly. Usealightengineorflushingoil to
cleanoutthehousings.
Note:Donotusewater, steam,kerosene, orgasolineforflushing. Iftheoil isdecomposed,dismantlingisnecessary.
GOVERNOR.
Ateachlubrication,checktheoillevelinthegovernorhousing.Useoil ofthesamegradeusedintheengineto
maintainthelubricantatfillerpluglevel. Drainandrefillthehousingateachengineoilchange.
POWERTAKE-OFF SHAFTAND PULLEYDRIVEHOUSINGS.
Checkthelubricantlevelateachlubricationjob, maintaining thelubricantatfillerplug level. Shouldthepower
take-offbeusedfrequently, changethelubricanteach300 hours.
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