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My 67 CJ5 build

Discussion in 'Builds and Fabricators Forum' started by Johns1967CJ5, Dec 11, 2013.

  1. Mar 2, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    So I read Rick Stivers article again on the T-90 rebuild and he ran into the same issue with the spacers not being flush with the ends of the countershaft, so as he recommends I added a washer to each side and It brought the washers pretty close to flush. As for the front countershaft washer here is a photo. I decided to get a new one after looking at the damage again.

    [​IMG]
     
    Last edited: Aug 31, 2017
  2. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    While waiting for another thrust washer for transmission I assembled the transfer case. I followed Stivers directions as well as referencing a couple of other sites. So if these posts look familiar that's why

    I laid out all the parts to get some organization

    [​IMG]
     
    Last edited: Aug 29, 2017
  3. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Started with speedometer gear

    [​IMG]
    [​IMG]

    Nextt the bearing and snap ring
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    used a seal installer to seat the bearing
    [​IMG]
    [​IMG]
     
    Last edited: Aug 29, 2017
  4. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Output clutch shaft going in
    [​IMG]

    [​IMG]

    Short shift shaft with fork
    [​IMG]

    Output clutch gear
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    Installed with shift fork
    [​IMG]
     
    Last edited: Aug 31, 2017
  5. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    I painted everything on the case then sanded the mating surfaces so I can see any high spots.

    [​IMG]

    [​IMG]

    Long shifting shaft with fork

    [​IMG]

    [​IMG]

    Used a deep socket to put on new bearing to output shaft

    [​IMG]

    [​IMG]
     
    Last edited: Aug 31, 2017
  6. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Sliding gear on the shift fork

    [​IMG]

    output shaft gear

    [​IMG]

    output shaft slid in

    [​IMG]

    next the thrust washer with the tab inserted in the shaft groove that goes back thru the gear

    [​IMG]

    Snap ring

    [​IMG]

    washer and snap ring installed

    [​IMG]
     
    Last edited: Aug 31, 2017
    Hellion likes this.
  7. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Bearing installed

    [​IMG]

    bearing cup

    [​IMG]

    tapped the bearing cup flush, bearing cover will seat it the rest of the way

    [​IMG]

    temporarily installed the front cap with gasket ( without sealer ) so I can set up end play on shaft

    [​IMG]
     
    Last edited: Aug 31, 2017
  8. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    I read setting up the rear cap shims were a pain in the butt and they were

    [​IMG]

    After many tries finally set the end play at 0.005

    [​IMG]

    sprayed the shims with copper form a gasket

    [​IMG]

    slipped on speedo gear

    [​IMG]

    rear bearing cap installed

    [​IMG]
     
    Last edited: Sep 2, 2017
  9. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Removed front cap and installed seals

    [​IMG]

    interlocking pin

    [​IMG]

    pin shouldn't protrude. move shaft if it does

    [​IMG]

    I used gasket shellac on all the gaskets

    [​IMG]

    front cap installed

    [​IMG]
     
    Last edited: Sep 2, 2017
  10. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    On to the intermediate shaft

    [​IMG]

    I used a 1 1/4" wood dowel cut to 2 5/8" long to keep everything in place. Added first washer then 24 needle bearings, center washer then 24 more bearings, than last washer. I coated inside of shaft with assembly grease first

    [​IMG]
    [​IMG]
    [​IMG]

    Applied thrust washers to case with assembly grease to stick them, then put a dowel in each side to hold them

    [​IMG]
     
    Last edited: Sep 2, 2017
  11. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    Slid the gear into case and pushed in dowels a bit to hold it in place

    [​IMG]

    removed the first dowel then slid in the shaft making sure I did not catch the edge of any of the needle bearings. If it works the shaft should push out the other dowels

    [​IMG]

    shafts in

    [​IMG]

    locking plate installed

    [​IMG]
     
    Last edited: Sep 2, 2017
  12. Mar 4, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    I then added poppet balls and springs to the front cap, Before doing this the shifting shafts moved freely, after, I couldn't budge them. I hope that is right. I believe thats what they are designed to do, keep the shafts from moving to free

    [​IMG]

    [​IMG]

    rear seal installed

    [​IMG]

    oil pan gasket and sealer

    [​IMG]

    [​IMG]

    [​IMG]

    Love making these things new again :)

    [​IMG]

    [​IMG]

    Just have to blast and paint E-brake drum and backing plate and install.
    Transmission next
     
    Last edited: Sep 2, 2017
  13. Mar 5, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    I decided to get the drive shaft yoke blasted and painted, A coat of Por-15 and then some cast iron grey from Eastwood

    [​IMG]

    Felt seal applied

    [​IMG]

    Used an impact gun to tighten washer and nut

    [​IMG]

    A reminder to me to torque the nut after case is mounted for leverage

    [​IMG]
     
    Last edited: Sep 2, 2017
  14. Mar 6, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    First tool to buy to do a restoration ? Blast cabinet :)

    [​IMG]

    Cracked E brake drum......more money

    [​IMG]
     
    Last edited: Sep 2, 2017
  15. Mar 11, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

    Northern NJ
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    I got all the parts in for the transmission and got it rebuilt. I got the transfer case mated with the transmission again, took apart the shift housing and cleaned, sandblasted and painted it. Both trans. and TC shift great.

    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]
     
    Last edited: Sep 2, 2017
    Hellion likes this.
  16. Mar 12, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    Got the pto back together and installed on transfer case today

    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: Sep 2, 2017
  17. Mar 12, 2014
    58 willys

    58 willys Sponsor

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  18. Mar 14, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    I am running out of things to rebuild before starting the chassis assembly, so I called the machine shop and told them I wanted to get the engine block of the V6 odd fire cleaned and prepped and he laughed at me! Said " why the heck are you bothering with that thing " :rofl: guess I will rebuild the winch Instead lol.
     
  19. Mar 28, 2014
    Johns1967CJ5

    Johns1967CJ5 Sponsor

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    Nos front bumper came today from willys motors :)

    [​IMG]
     
    Last edited: Sep 2, 2017
  20. Mar 28, 2014
    68BuickV6

    68BuickV6 Well-Known Member

    Hesperia, CA.
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    :drool:
     
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