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Mission Impossible 1956 Cj5 Basket Case.

Discussion in 'Builds and Fabricators Forum' started by Rodney, Jan 9, 2021.

  1. Jan 9, 2021
    Rodney

    Rodney Member

    Sierra Foothills
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    I just joined the Forum and the introduction was getting a little long, so here is the start of my latest build.
    I was given a 56 CJ5 that was partily disasembled almost 30 years ago. It had a worn out 289 with a t90 when it was last run. The last owner picked up a Ford bell housing with a "RUG" 4 Speed Toploader with adapter plate and Dana 18 transfer case. Which he left outside for decades. First thing I did was bring the Tranny/transfer case home to see if any of it was useable. So now the work begins.
     
    Last edited: Jan 9, 2021
  2. Jan 9, 2021
    jeep peep69

    jeep peep69 Member 2021 Sponsor

    redding ca.
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    Oh man and I thought mine was rough I think yours maybe a step ahead off mine good luck look forward to seeing your progress.
     
    Rodney likes this.
  3. Jan 10, 2021
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2021 Sponsor 2020 Sponsor

    Hills of NH
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    Looks like a military windshield.
     
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  4. Jan 10, 2021
    Rich M.

    Rich M. Shoe salesman

    Maryland
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    Welcome and cool project. Hope the rug and adapter are salvageable, great combo.
     
    Rodney likes this.
  5. Jan 10, 2021
    Rodney

    Rodney Member

    Sierra Foothills
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    Yeah, this old CJ5 has seen better days. But it seems to be mostly all there. I still haven't dug through the Chicken Coop where the steering column, gearbox and steering wheel are supposed to be. Along with the brake and clutch pedals.
     
    ITLKSEZ, Rich M. and Mr Vaughan like this.
  6. Jan 10, 2021
    Rodney

    Rodney Member

    Sierra Foothills
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    [/GALLERY]
    [/GALLERY]
    1.The first picture is where I found the Transmission/Transfer case. Outside in the rain.

    2. Opened up to find a mess that looks like it spent 30 years on the bottom of Lake Tahoe.
    3. After two days in Cleaning Vinager, a good pressure wash, two more days filled with ATF/GM Auto track 2 fluid and then a day in the solvent tank it came free and spun and shifted.
    4. Total dissasemble, new main bearings ,needles and roller bearings, small parts kit and new seals and gaskets, and the Rug 4 speed is back together. I am absolutly amazed at how hard the gears and shaft are in this Ford Toploader. The Dana 18 Transfer case was rusted to junk and I was only able to salvage the speedo drive gear.
     
    Last edited: Jan 13, 2021
    Danefraz, ITLKSEZ, 73 cj5 and 7 others like this.
  7. Jan 10, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

    Central City, NE
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    at least the jeep itself doesnt seem too rusted? :shrug: most of the issues with mine are rust from NY
     
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  8. Jan 10, 2021
    Rodney

    Rodney Member

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    As long as you stay off Interstate 80 over Donner Summit in the winter, we don't have much salt issues out here. Of course, I haven't even washed it yet, but the floor boards even look to be in good shape. After a pressure was and some sand blasting, who knows what I'll find.
     
  9. Jan 10, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

    Central City, NE
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    you're in california, so likely not bad.
     
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  10. Jan 10, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

    Central City, NE
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    you could likely find a Dana 20 with the right driver gear, then a centered rear D44, with more aftermarket support for the 30 spline shafts. these would come out of later vehicles, the axle out of a later 5 and the t-case from many different applications.
     
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  11. Jan 10, 2021
    Rodney

    Rodney Member

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    I have another Dana 18 in good condition that I will post more pictures later. I haven't even gotten to axles yet. I figured if the Tranny and transfer case were doable, the rest would fall in line.
     
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  12. Jan 10, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

    Central City, NE
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    ok, that'd be good, the axles would match up. just recommending.
     
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  13. Jan 10, 2021
    Rodney

    Rodney Member

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    Thanks Tyler for the recomendations. Like I said I have another Dana 18 from the 1963 Willys Wagon project I finished back in 2015. The Wagon Dana 18 didn't use the e-brake drum.The axles in the wagon were rusted into the ground, and I opted to use 2003 Land Rover Disc Brake axles and transfer case in the Wagon.
    The P/O of the CJ5 claimes all the brakes are new including drums and wheel cylinders. If thats the case I will use them. If not, I'll make a decision later.
     
  14. Jan 10, 2021
    Rodney

    Rodney Member

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    The Dana 18 from the Wagon project was in very good condition, but to use it in the CJ5 I needed to come up with an output shaft E-Brake. I scrounged through some milk crates in my barn and came up with a few pieces.

    Then did a little lathe work to make a 1977 Kawasaki KZ750 front rotor fit the 4 bolt Dana output flange.

    I made up a paper patern and cut a bracket out of 1/4" T6 aluminum and mounted a Wilwood caliper to the two lower output bearing retainer housing bolts. The Wilwood Caliper uses two opposing pistons so no need to have a floating bracket.


    A new gasket and seal kit, a fresh coat of paint and the transfer case is ready to go.

     
    Last edited: Jan 10, 2021
    Danefraz, timsresort, AKjeff and 8 others like this.
  15. Jan 10, 2021
    Rodney

    Rodney Member

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    There are a ton of Hydraulic ratchting E-Brakes handle on Flee-Bay resonably priced. Most are avaliable with their own Master Cylinder/Resevoir that is totaly sperate from the main Brake system. I know it will bleed off eventualy. But the point of an e-brake in my opinion is to momentarily hold you on a hill, or to stop it from roling away while warming it up in the morning, not to park it and walk away for a few days without putting it gear.

    HYDRAULIC ALUMINUM EMERGENCY HAND BRAKE HANDLE E-BRAKE LEVER MATTE BLACK | eBay
     
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  16. Jan 10, 2021
    Rodney

    Rodney Member

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    Not sure, but definaly earlier than 56.
     
  17. Jan 10, 2021
    Mr Vaughan

    Mr Vaughan Fly by the seat of your pants

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    until '55 only the military had the '5 body style, so it's likely a military one - but i could be wrong
     
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  18. Jan 12, 2021
    Rodney

    Rodney Member

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    I spent some time today and made up the shift links for the Rug Toploader. The Hurst Pro Comp shifter that came with it had some really badly modified Chevy Arms and links. Looked like a mass wet noodles all twisted around each other and would't shift. I ordered the correct Ford shift arms and used aluminum tubing with Heim joints for 1-2 and 3-4 and then used a chrome plated bronze Marine turn buckle for reverse. I like the way it came out and it shifts nice and crisp.

    I'm still waiting for the Dana 18 Anti-Rattle springs for the shift levers so I haven't set the pivot pins yet.

    But Now that I know it shifts, I finished with the new top gasket and cover on the transmission.
    I still need to find a 29 tooth main shaft gear and then I can tighten up the PTO cover. The first Transfer case had the 26 tooth and this one uses the 29 which I don't have. Time to order from Crown.
     
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  19. Jan 16, 2021
    Rodney

    Rodney Member

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    I brought home the CJ5 today along with a trailer load of parts and pieces and rats nest.
    My wife took pictures and sent them to her supervisor, Saying " My husband bought me a new Jeep, I think it'll buff out"!
    I unloaded every thing from the trailer and inside the CJ5, removed the windshied and dash, cut out all the old wireing, and stripped the dash of everything. Then I spent an hour or more pressure washing it.
    Found some cancer, and a couple of cracks in the body, rust in the floors. Nothing unexpected except the plywood screwed to the back of one panel to hold the bondo in.
    It apears to have been Turquoise under several coats of paint, some brushed on with a broom. No patina worth saving here.
     
  20. Jan 16, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2021 Sponsor 2020 Sponsor

    New Kent, VA
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    Welcome to the forum, and it looks like you've made some good progress in a short period of time! I'm looking forward to seeing what you do with it.
     
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