Diesel CJ5 Rebuild

I towed this CJ5 home from near Hartford, CT just about 1.5 years ago. It was in pretty good shape overall. It’s a 62 that’s was well used but there is much less rot on it than any of the other jeeps I have and I know it has been in New England since at least 77.





The CJ was really optioned out when I got it. Besides the Perkins motor it has power locks in the front and rear, a Warn O/D, 2 aux. fuel tanks w/ a transfer pump to move the fuel to the main tank and a Ramsey DP-1 (front and rear) pto.

Rear Fender Fuel Tank



I had to bleed all the injector lines to get the motor to run but once I did it ran great. The only problem was that the jeep wouldn't move under its own power. A few weeks later I started tearing down the drivetrain and found that all the teeth on the overdrive input shaft were ground down.



I sent the O/D off to Herm to be rebuilt. I also took the trans and transfercase apart and found that they were in desperate need of a rebuild as well. It seems the gear remnants from the O/D made there way through the trans/t-case and really chewed up the bearings and thrust washers.

At this point I have the transmission and the pto rebuilt. The transfercase is almost done and just needs some final assembly. I’ve also started replacing the entire brake system. The rubber lines that were on it had started to crack and the steel lines were rusty. I have a number of new ‘while I’m in there’ parts like wheel bearings, clutch, and drivetrain mounts.

I think I’m in the home stretch and hope to be driving this thing in a few weeks.

I have lots of pics and will post some more soon. I just wanted to get this thread started before the jeep was done.

-Dean

 

Woah! I didn't realize those pics would be so big. I'll try to resize them.

 

Way cool. Can you post some pics of the engine?

 

Here are a few picture of the engine. You can see the two batteries in the first picture. That was stock on the diesel powered CJs as far as I can tell.





This is a picture of the injection pump. I couldn’t really get a good shot will the hoses in the way.




-Dean

 

nice pics! You are one lucky guy to get your hands on one of these. I want a diesel CJ5 really bad. Just cuz they are so hard to find. Plus I like diesel power. Good luck and keep us posted.

 

I am a big diesel fan and I am very envious of your Jeep. I am doing an engine swap to a diesel in my 98 TJ.

 

Wow, what a rare find. Great project!

 

Very cool , Could you get pics of the bell housing? Thanks.

 

Great Jeep! That grill makes it look like a Series II Land Rover. I've never seen a wheel-well fuel tank,that's interesting. I'd worry about a tire throwing a rock into it, but with diesel at least it probably wouldn't explode.

 

Can you post another picture of the grill, looks very interesting!

 

Hi Guys,

Here are some pictures of the bellhousing. I left the paint on it in the event that I decide to restore this jeep someday I might be able to determine the original bellhousing color. If anyone is interested I can take some measurements or trace the pattern for them.





Here is a close up of the relief cut need to clear the rear master cylinder bolt. The little filler plate is riveted on.


-_Dean

 

Here are a few pictures of the grill. I have talked to a few other Perkins power CJ owners and none of them have these shutters. I assume it was not a factory installed part.



The shutters that are controlled with a twist lock T-handle on the dash.


-Dean

 

Your bell housing looks to be a standard SAE # 5 or 6 pattern.
Here is a chart that gives the dimentions for the SAE bell housings.
http://www.garbee.net/~cabell/sae.htm

 

Aftermarket

http://users.erols.com/b-dwheeler/indexshut.html

 

Happy Friday guys!!!! My weekend began at 7 this morning. I just finished 4 weeks of 7pm to 7am test coverage at work. On Monday I can go back to my old 1st shift schedule and hopefully put some time into getting this jeep done.

I though I was going to make a lot of progress last weekend but the clutch kit I order came with the wrong friction disc. The clutch I took out of this jeep was the HD 9.25 in dia. I ordered a new kit from Parts America (P/N MU16761B) but it had the 8.5 in dia disc instead of the 9.25. The new kit arrived at my local Advance Auto yesterday but I haven’t had a chance to pick it up yet. Hopefully I can start bolting stuff in later this afternoon. The new goal is to take the 5 around the block before the 4th of July.

I know everyone likes pictures so I share some of the ones I’ve taken during my rebuilt thus far.

When I drained the T90/D18 I got at least ¾ of a gallon of water out of them. Both cases were full of metal shavings and the gear teeth were in bad shape.

Here are thrust washers that came out of the D18


This is what was in the recently rebuilt transmission I picked up for parts.

I think this failure was caused but the rollers having too much room to move axially in the cluster gear. When a few start to walk away from the rest of them they get a little sideways and snap off. When I rebuilt mine I used some of my old spacer washers to fill up that empty space and keep the rollers aligned.

Here are some of the drivetrain components I rebuilt. I didn’t get very creative with the colors…The cast aluminum I painted with cast aluminum engine enamel. Can you guess what color the cast iron is??

The DP1 when I took it out. Both detent springs were broken so I couldn’t tell how many positions each lever had.

Exploded view of all the parts.

Assembled.


The rebuilt D18, had one broken detent spring.

Rebuilt T90, had one broken detent spring.

Here is everything on a bench in my basement awaiting installation. The OD is still wrapped up in the box Herm sent it in.



-Dean

 

very clean and tidy. gonna be a cool rig

 

I am sooooo jealous

 

Very nice! Are you going to put some sealant on the end of the countershaft to make sure it doesn't leak?

 

I think its time to start up this tread again. In my last post I had planned to take the CJ5 around the block. Needless to say, I’m a little behind schedule.

I moved to a new apartment in September, so most of my late summer was spent packing and very little was done on the jeep.

For the past few weeks I’ve stepped up the effort and last night I finished rebuilding the driver’s side hub. I did the king pin bearings, new brakes, everything cleaned and painted.

The end is really in site now (just in time for winter), just little things let to do like clutch linkage, 2 brake lines, O/D linkage, etc.

One thing I noticed while reinstalling the knuckle is that the plow frame interferes with the tie rod. When I was pushing the jeep into my new apartment’s garage back in September I noticed that the tires didn’t turn very far but I did have time to investigate the cause at the time. From what I can tell the tie rod hits the plow frame brackets that clamp down on the spring packs just in from of the axle. I guess it doesn’t really matter since I plan to remove the plow frame anyway but have you guys seen this problem before?