Jeep CJ/Scrambler 1971-86 Repair Manual

The Willys CJ is a public adaptation of the distinguished Willys Military Jeep from World War II.

The initial CJ prototype was introduced inside 1944 by Willys, as well as the same standard car stayed inside manufacturing from 7 variants plus 3 business parents till 1986.

A variant of the CJ continues to be inside manufacturing now below license. The last CJs, the CJ-7 plus CJ-8, were changed inside 1986 by the Jeep Wrangler.

Additionally accessible were two-wheel-drive variants, termed as DJs. A drawbar is a strong coupling between a hauling car as well as its hauled weight. Drawbars are inside well-known utilize with rail transport, road trailers, both big plus little, commercial plus recreational, plus with agricultural equipment.By 1944, the Allies were confident the war will be claimed. This authorized Willys with consider designing a Jeep for the post-war civilian marketplace. Documentation is scarce, however, it appears a Willys-Overland CJ-1 was running by May of which year. The CJ-1 was apparently an MB which had been modified by adding a tailgate, drawbar, along with a civilian-style canvas top. None of the CJ-1s built have survived, plus it is very unknown how various were built.
The Willys MB U.S. Army Jeep as well as the Ford GPW were produced from 1941 with 1945. These little four-wheel drive utility cars are considered the iconic World War II Jeep, plus inspired several synonymous light utility cars. Over the years, the World War II Jeep later evolved into the "CJ" civilian Jeep. Its counterpart inside the German military was the Volkswagen Kübelwagen, initially prototyped inside 1938, equally based about a little vehicle, however, that utilized an air-cooled engine plus wasn't four-wheel drive.

Even though the planet had enjoyed common mechanisation of the military throughout World War I, as well as the United States Army had absolutely utilized four-wheel drive pickups inside it, provided by the Four Wheel Drive Car Co.; by the time World War II was dawning, the United States Department of War were nonetheless looking a light, cross-country reconnaissance car.

As tensions were heightening all over the world inside the late 1930s, the U.S. Army asked American vehicle producers with tender suggestions with substitute its existing, aging light engine cars, largely motorcycles plus sidecars and several Ford Model Ts. This lead to many prototypes being presented with military officials, like five Marmon-Herrington 4x4 Fords inside 1937, plus 3 Austin roadsters by American Bantam inside 1938. But, the U.S. Army's needs were not formalized till July 11, 1940, whenever 135 U.S. automotive producers were contacted with submit a shape conforming with the army's requirements for a car the World War II technical guide TM 9-803 described because "... a general cause, personnel, or cargo carrier particularly adaptable for reconnaissance or control, plus designated because 1/4-ton 4x4 Truck."
Marmon-Herrington converted Ford 1/2 lot truck, occasionally called the "Grandfather of the Jeep"

By today the war was below technique inside Europe, thus the Army's need was urgent plus demanding. Bids were with be received by July 22, a span of only eleven days. Manufacturers were provided 49 days with submit their initially prototype plus 75 days for completion of 70 test cars. The Army's Ordnance Technical Committee requirements were equally demanding: the car will be four-wheel drive, have a team of 3 about a wheelbase of no over 75 inches plus tracks no over 47 inches, feature a fold-down windshield, 660 lb payload plus be driven by an engine capable of 85 ft·lb of torque. The most daunting need, yet, was an clear fat of no over 1,300 lb.

Just 2 firms entered: American Bantam Car Company plus Willys-Overland Motors. Though Willys-Overland was the low bidder, Bantam received the call, being truly the only business committing with deliver a pilot model inside 49 days plus creation examples inside 75. Under the leadership of designer Karl Probst, Bantam built their initial prototype, dubbed the "Blitz Buggy", plus delivered it with the Army car test center at Camp Holabird, Maryland about September 23, 1940. This presented Army officials with all the initially of what eventually evolved into the World War II U.S. Army Jeeps: the Willys MB plus Ford GPW.
The Bantam no.1 'Blitz Buggy'

Because Bantam didn't have the creation ability or fiscal stability with deliver found on the scale required by the War Department, the different 2 bidders, Ford plus Willys, were encouraged with complete their own pilot models for testing. The contract for the hot reconnaissance vehicle was with be determined by trials. As testing of the Bantam prototype took spot from September 27 with October 16, Ford plus Willys technical representatives present at Holabird were provided ample chance with research the vehicle's performance. Moreover, inside purchase with expedite creation, the War Department forwarded the Bantam blueprints with Ford plus Willys, declaring the government owned the shape. Bantam didn't dispute this move due with its precarious financial condition. By November 1940, Ford plus Willys every submitted prototypes with compete with all the Bantam inside the Army's trials. The pilot models, the Willys Quad as well as the Ford Pygmy, turned out pretty synonymous with every alternative plus were joined inside testing by Bantam's entry, today evolved into a Mark II called the BRC 60. By then your U.S. as well as its armed forces were absolutely below these stress which all 3 vehicles were announced acceptable plus orders for 1,500 units per firm were provided for field testing. At this time it was recognized the authentic fat limit was unrealistic, plus it was raised with 2,160 lb.

For these respective pre-production runs, every car received revisions along with a unique name. Bantam's became the BRC 40. Production started about March 31, 1941, with a total of 2,605 accumulated with December 6. The firm couldn't meet the Army's need for 75 Jeeps a day, creation contracts were equally granted with Willys plus with Ford.

After reducing the vehicle's fat by 240 pounds, Willys' changed the designation with "MA" for "Military" model "A". The Fords went into creation because "GP", with "G" for a "Government" kind contract plus "P" popular by Ford with designate any passenger vehicle with a wheelbase of 80 inches.
Willys MA jeep at the Desert Training Center, Indio, California, June 1942
Willys MB chosen by previous Philippine President Ramon Magsaysay

By July 1941, the War Department desired with standardize plus decided with choose a single maker to provide them with all the upcoming purchase for another 16,000 cars. Willys earned the contract largely due with its more effective engine that soldiers raved about, as well as its lower expense plus silhouette. The shape attributes the Bantam plus Ford entries had that were an improvement over Willys' were then included into the Willys auto, moving it from an "A" designation with "B", therefore the "MB" nomenclature. Many notable had been a flat broad bonnet, modified from Ford GP.

By October 1941, it became obvious Willys-Overland couldn't continue with creation need plus Ford was contracted with provide them too. The Ford vehicle was then designated GPW, with all the "W" referring with the "Willys" certified shape. During World War II, Willys yielded 363,000 Jeeps plus Ford several 280,000. Approximately 51,000 were exported with the U.S.S.R. below the Lend-Lease system.

A further 13,000 amphibian jeeps were built by Ford beneath the name GPA. Inspired by the greater DUKW, the car was yielded too rapidly plus proven with be too thick, too unwieldy, plus of insufficient freeboard. In spite of participating effectively inside the Sicily landings many GPAs were routed with the U.S.S.R. below the Lend-Lease system. The Soviets were sufficiently happy with its ability with cross streams with develop their own adaptation of it following the war, the GAZ-46.
Although it bore the CJ name, the Willys-Overland CJ-2 wasn't certainly accessible at retail. The CJ-2s, sometimes known because "AgriJeeps," were the next generation prototype for the initially creation civilian Jeep, plus were employed entirely for testing reasons. It was straight based found on the military Willys MB, utilizing the same Willys Go Devil engine, however, stripped of all military qualities, especially the blackout light. They had tailgates, Power Take-offs, engine governors, column-shift T90 manual transmissions, 5.38 gears, 2.43:1 low-range transfer situations, plus driver's-side tool indentations. The earlier models had brass plaques found on the bonnet plus windshield which read "JEEP". Later models were stamped "JEEP" a la the familiar "WILLYS" stamping which appeared found on the CJ-2A plus later models. Many CJ-2s had "AgriJeep" plaques affixed with the dash. The spare tire was installed forward of the passenger-side back wheel found on the earlier models plus aft of the back wheel about later ones. It appears which CJ-2s were distributed with "agricultural stations" for evaluation reasons. Of the 45 CJ-2s built, serial numbers CJ2-06, CJ2-09, CJ2-11, CJ2-12, CJ2-14, CJ2-26, CJ2-32, CJ2-37 plus CJ2-39 have survived. Just CJ2-09 has been restored.
The classes learned with all the CJ-2 led with the development of the initially full-production CJ, the 1945-1949 Willys-Overland CJ-2A. The CJ-2A looked a lot like a civilianized MB with a tailgate plus side-mounted spare tire. One main difference amongst the MB as well as the CJ-2A was the grilles of the 2 cars. The MB had recessed headlights plus nine-slot grilles whilst the CJ2A had greater headlights flush-mounted inside a seven-slot grille. In region of the MB's T-84 transmission, the CJ-2A was loaded with the beefier T-90 three-speed transmission. The CJ-2A was nevertheless driven by the reliable L-134 Go-Devil engine. Many of the early CJ-2As were yielded utilizing excess military Jeep components like engine blocks plus, inside a limited situations, modified frames. Many of the utilization of excess components was due with strikes at dealers like Autolite. Since Willys yielded some components in-house plus relied seriously about dealers, it was vulnerable with strikes. Unfortunately for Willys, strikes were popular postwar. This definitely provided with low creation totals inside 1945 plus early 1946.

Because the CJ-2A was mainly intended for farming, ranching, plus commercial applications, a broad range of extras were accessible these as: back seat, center rear-view mirror, front passenger seat, canvas top, front PTO, back PTO, belt pulley drive, capstan winch, governor, back hydraulic lift, snow plow, welder, generator, mower, disk, front bumper fat, heavy-duty springs, double vacuum windshield wipers, double taillights, hot-climate radiator, driveshaft guards, heater, side methods, plus radiator brush protect.

CJ-2As were yielded with specific, lively color combinations which inside several methods symbolized the hope plus promise of postwar America. From 1945 with mid-1946, CJ-2As were just obtainable in 2 color combinations: Pasture Green with Autumn Yellow wheels plus Harvest Tan with Sunset Red wheels. More color combinations added inside mid-1946 were: Princeton Black with Harvard Red or Sunset Red wheels, Michigan Yellow with Pasture Green, Sunset Red or Americar Black wheels, Normandy Blue with Autumn Yellow or Sunset Red wheels, plus Harvard Red with Autumn Yellow or Americar Black wheels. The Pasture Green plus Harvest Tan combinations were dropped later inside 1946. The Harvard Red combinations were dropped inside 1947 plus changed with Picket Gray with Harvard Red wheels, plus Luzon Red with Universal Beige wheels. In 1948, the following color combinations were moreover added: Emerald Green with Universal Beige wheels, Potomac Gray with Harvard Red or American Black wheels. For 1949, the Picket Gray, Michigan Yellow, plus Normandy Blue combinations were dropped. Olive drab was equally accessible for export models.

On early CJ-2As, the front seats were covered inside olive drab plastic. Around mid-1947, Slate Gray plastic became accessible for certain color combinations. Later, Barcelona Red was put into the blend.

A total of 214,760 CJ-2As were yielded.The Willys-Overland CJ-3A was introduced inside 1949 plus was inside manufacturing till 1953 whenever changed by the CJ-3B. It was driven by Willys' 60 HP L-134 "Go-Devil" 4-cylinder engine, with a T-90 transmission plus Dana 18 transfer case, a Dana 25 front axle plus Dana 41 or 44 back axle. It showcased a one-piece windshield with a vent and also wipers at the bottom. The CJ-3A had beefed up suspension to support the different agricultural implements that have been being built for the car. Another difference had been a shorter back wheelwell found on the 3A compared with 34 inside found on the 2A) plus moving the motorists seat rearward. A bare-bones Farm Jeep variation was accessible beginning inside 1951 with a force takeoff. 131,843 CJ-3As were yielded before the series ended inside 1953. Regarding 550 of the CJ3-A were assembled by Mitsubishi because the J1/J2 inside late 1952 plus early 1953, only for the Japanese authorities plus forestry agency.
The Willys F4-134 Hurricane was an inline-4 piston engine plus driven the distinguished Jeep CJ inside the CJ-3B, CJ-5, plus CJ-6 models. It was additionally chosen inside the Willys 473 plus 475 pickups, wagons, plus sedan deliveries. It changed the Willys Go Devil engine which was selected inside the M8 Jeep plus alternative early Jeep-based models like the Jeepster. This engine was equally built by Mitsubishi for their license-built Jeep, and also additional applications.
The Hurricane was based found on the earlier Go-Devil flathead engine. To receive more energy within the engine, the induction program was change within the Go-Devil's side-valve configuration with an inlet-over-exhaust configuration, or "F-head". This permitted the valves with be bigger as well as the combustion room with be small, improving flow plus improving the compression ratio. The compression ratio rose from 6.5:1 inside the Go-Devil engine with 7.5:1 inside the Hurricane engine, though a variation of the Hurricane engine was created with a 6.9:1 compression ratio.
The L134 Go Devil was up-to-date with all the F-head with become the F134 inside 1950. This engine yielded a gross output of 75 hp at 4000 rpm plus 114 lb·ft of torque at 2000 rpm with a 7.5:1 compression ratio. The gross energy plus torque outputs fell with 72 hp plus 112 lb·ft respectively whenever the engine had a 6.9:1 compression ratio. Bore plus stroke dimensions were the same because the L-head engine at 3 1⁄8" x 4 3⁄8" providing 134.2 cu inside.

The F4-134 was introduced inside 1950 inside the Jeep Truck. Vehicles with this engine were provided the model designation 4-73. This engine wasn't located inside a CJ till the introduction of the CJ-3B inside 1953, that had a distinctive significant bonnet to support the much taller engine. The engine stayed inside manufacturing till 1971, following American Motors Corporation bought Kaiser Jeep.
The Willys CJ-3B changed the CJ-3A inside 1953, the same year Willys was available with Kaiser. Kaiser removed "Overland" within the subcompany name. CJ-3B introduced a high grille plus bonnet with clear the modern Willys Hurricane engine. A four-speed guide transmission became optional inside 1963, at an additional expense of 4. The turning radius was 17 ft 6 inside. The CJ-3B was yielded till 1968 with a total of regarding 196,000 yielded, though the shape was equally certified with a quantity of global producers, including Mitsubishi of Japan plus Mahindra of India. Mitsubishi's variation was built from 1953 till 1998, whilst Mahindra continued with make cars based found on the Willys CJ-3B till October 1, 2010. The CJ-3B was additionally built by Türk Willys Overland. It was the initial car plant with be opened inside Turkey, inside 1954.

The M606 had been a militarized adaptation of the Jeep CJ-3B.
The Willys CJ-5 was influenced by hot business owner, Kaiser, as well as the Korean War M38 Jeep. It was intended with substitute the CJ-3B, however which model continued inside manufacturing. The CJ-5 repeated this pattern, continuing inside creation for 3 years whilst 3 new models appeared. "The CJ-5 has the distinct honor of being a car that has been hard with kill off... equaling the greatest creation run of note." The numerous changes throughout this very extended creation run nevertheless lead to low components compatibility between early plus late model CJ5s despite sharing the same name. A total of 603,303 CJ-5s were yielded between 1954 plus 1983.

From 1961 with 1965, optional for the CJ-5 plus CJ-6 was the British-made Perkins 192 cu inside Diesel I4 with 62 hp at 3,000 rpm plus 143 lb/ft at 1350 rpm.

In 1965, Kaiser purchased the casting rights with the Buick 225 cu inside V6 Dauntless as well as the CJ-5 plus CJ-6 got a modern engine with 155 hp supplementing the four-cylinder Willys Hurricane engine. Power steering had been a choice.
Willys M38A1

Side-marker lights were added inside 1969.

The business was available with American Motors inside 1970, as well as the GM engine was retired following the 1971 model year. The "Trac-Lok" limited-slip differential changed the "Powr-Lok" inside 1971.

American Motors started utilizing their own machines inside 1972. Replacing the Hurricane was the one-barrel 232 cu inside. Optional had been a one-barrel 258 cu inside. Both machines selected the Carter YF carburetor. Additionally inside 1972, AMC's 304 cu inside V8 engine became obtainable in the same tune because a base V8 muscle vehicle. To accommodate the unique motors, the fenders plus bonnet were stretched 5 inside beginning inside 1972 as well as the wheelbase was stretched 3 inside. Other drive train changes took region then too, including the front axle becoming a full-floating Dana 20. In 1973, a new dash was selected, with a single gauge inside the center of the dash housing the speedometer, gas plus temperature gauges.

In 1976, the tub plus frame were modified somewhat from earlier versions. The frame went from an open channel with boxed inside front of the back axle, as well as the body tub became more rounded. The windshield frame plus windshield angle were furthermore changed, meaning which tops from 1955 with 1975 will likely not fit a 1976-1983 CJ-5 plus vice-versa. The back axle was equally changed inside 1976 from a Dana model 44 with an AMC-manufactured model 20 that had a larger-diameter ring gear however, utilized a two-piece axleshaft/hub assembly rather of the stronger one-piece shape employed inside the Dana. But, certain early-production 1976 CJ-5's retained the elder Dana model 44 till stock of these was depleted.

For 1977, energy disk brakes as well as the "Golden Eagle" package were new choices.

In 1979, the standard engine became the 258 cu inside I6 which today showcased a Carter BBD two-barrel carburetor.

An AM/FM radio became optional inside 1981.

From 1980 with 1983, the CJ-5 came standard with a "Hurricane"-branded adaptation of the GM Iron Duke I4 with an SR4 close-ratio four-speed manual transmission. The 258 cu inside I6 stayed accessible because a choice, however the transmission was changed within the Tremec T-150 3-speed with a Tremec T-176 close-ratio four-speed. The Dana 25 front axle was retained, however the locking hubs were changed with ones utilizing a five-bolt retaining pattern.

The CJ-6 was just a 20 inside longer-wheelbase CJ-5. Introduced inside 1955 because a 1956 model, the CJ-6 was not popular inside the United States. Most CJ6 models were available with Sweden plus South America. The U.S. Forest Service place a amount of CJ-6 Jeeps into utilize. American sales ended inside 1975. Simply 50,172 had been prepared whenever the series went from manufacturing completely inside 1981. Simply because inside the CJ-5, the V6 plus V8 engine options appeared inside 1965 plus 1972.

The military variation, the M170, really entered creation inside 1953. It shared most highlights of the M38A1, however, had the passenger door starting extended back with the back wheel effectively. Most were selected because front-line field ambulances, capable with carry 4 litters. A limited were equally selected because radio units.

The Brazilian Willys factory developed a adaptation of the CJ5 rather synonymous with the CJ6, available with either 2 or 4 doorways. Called the "Willys Jeep 101" it shared the chassis of the neighborhood Rural, a redesigned Willys Jeep Station Wagon. Like the Brazilian-made CJ5s, the 101 has square back wheel openings. This variation was introduced inside 1961 nevertheless wasn't retained following Ford's takeover inside the fall of 1967.
The Jeep CJ-7 showcased a wheelbase 10 inches longer than which of the CJ-5 plus lacked its trademark back curve of the door cutouts. The different key difference with the CJ-5 was with the chassis that hitherto consisted of 2 parallel longitudinal leading c-section rails. To aid enhance car handling plus stability, the back section of the chassis stepped out with enable the road springs plus dampers with be installed closer with the outside of the body. It was introduced inside 1976, plus 379,299 were built throughout 11 years of creation.

The Jeep CJ-8 became a lengthy wheel-base variation of the CJ-7, introduced inside 1981 plus produced from 1986. It showcased a 103 inside wheelbase along with a removable half-cab, creating a little pick-up design box rather of using the separate pickup bed. CJ-8s employed the conventional transfer case with manual front-locking hubs with engage the four-wheel drive. Many had either a 4 or five speed guide transmission, nevertheless a 3 speed automatic transmission was a choice.

The expression "Scrambler" originates from an appearance package which several CJ-8's were built with, that included tape images plus specialized wheels. Former President Ronald Reagan owned a CJ-8 plus utilized it about his California Ranch.

A full size steel hardtop CJ-8 was prepared for the Alaskan Postal Service, utilizing proper hand drive plus automatic transmissions. Instead of the back tailgate, the steel hardtop used the hinged barn door starting with the back. There were just 230 yielded plus available inside the U.S. It was equally commonly available inside Venezuela plus Australia because the CJ8 Overlander, with tiny variations including full size back windows found on the Overlander. Steel hardtops selected about these postal Scramblers plus Overlanders were recognised as "World Cab" tops.

The Jeep CJ-10 became a CJ-bodied pickup truck based about a seriously modified Jeep J10 pickup truck. Produced from 1981 with 1985, it was available plus tailored for export markets; Australia inside certain. They showcased square headlights installed inside the fenders along with a nine-slot grille, a homage with the Willys MB employed inside World War II; all different civilian Jeeps had a seven-slot grille. The CJ-10 may have either a hardtop or perhaps a softtop. The truck might be prepared with handle either a 5,900 lb or 6,700 lb GVW. Three motors were offered; an 198 cu inside six-cylinder Nissan built diesel engine, an 151 cu inside 4 cylinder AMC built engine or perhaps a 258 cu inside six cylinder AMC built engine. The driveline was mostly within the greater J series pickups; consisting of either a 4 speed Tremec T177 guide transmission or perhaps a 3 speed TorqueFlite A727 automatic transmission, a New Process 208 transfer case, a semi-floating Dana 44 front differential, plus either a semi-floating Dana 44 or Dana 60 back differential, depending about GVW rating. Importation of the CJ-10 into Australia ended inside 1985 with all the drop of the Australian dollar's value causing the car with be more costly than its competitors.