1981 Jeep CJ5

[67C10Step]

I need another project about like I need to be ran over by my first one. I've always wanted another CJ since having my CJ7 many years ago. This CJ5 popped up at too good a price to turn down.
If I don't get tied up I will go get it this weekend. About 1.5 hours north of me.

[mongocanfly]

Looks real nice..!!..
I always wanted a cj7..

[Willowrun]

Nice looking CJ5. I have an '86 CJ7 and the best thing I did was to tear out all of the emissions. With the stock emissions, carb, and ignition you couldn't let it run in the garage for 20 seconds or your eyes would be watering from the exhaust fumes. I did what I remember being called a "nutter" mod with the emissions/ignition, and I also swapped to a different carb and now that 4.2 inline with 150K+ miles runs strong and clean.

Interested to see more of it once you have it.

[67C10Step]

Originally Posted by Willowrun

Nice looking CJ5. I have an '86 CJ7 and the best thing I did was to tear out all of the emissions. With the stock emissions, carb, and ignition you couldn't let it run in the garage for 20 seconds or your eyes would be watering from the exhaust fumes. I did what I remember being called a "nutter" mod with the emissions/ignition, and I also swapped to a different carb and now that 4.2 inline with 150K+ miles runs strong and clean.

Interested to see more of it once you have it.

Looks like the plan is to go pick it up this Sunday. Will shake down the good, the bad, and the ugly at that point. I know someone has installed a push button starter switch on it so I anticipate a lot of messed up wiring and such. Jeeps of this area are still as simple as our old trucks so I'll sort it out and fix it right.

[67C10Step]

It is in its new home. Figuring out what I got for my money right now.

[67C10Step]

Getting ready to get serious on transfer case and transmission removal.

[Willowrun]

What engine and transmission does it have? Why are you dropping the transmission and T-case?

[67C10Step]

Has the 258 inline 6 in it. Needs a new flywheel and starter so I figure I’ll put a clutch and throw out bearing in it while I have it all apart. Flywheel is seriously messed up teeth wise and ruined the starter.
This should get it running and driving and then I’m going to start a list on what else. May end up getting a new wiring harness as the wiring has been jacked with a good bit.
Engine numbers seem to point it to being 1983 and it has a T150 3 speed transmission with a Dana 20 transfer case. Those cannot be newer than 1979. While not overly crazy on the 3 speed the Dana 20 is a good case.

[Willowrun]

Following along as my CJ needs a clutch as it sometimes chatters when it's warm. Mine is the 4.2 with the 5 speed manual which I feel is the least desirable of the manual transmissions with the 4 speed being the best. I'd much rather have your 3 speed than this week 5 speed that likes to whine in 5th.

Interested to see how it goes for you. It seems there are a lot of clutch kits out there.

[67C10Step]

The good thing is it appears the clutch and flywheel pretty much remained the same for years on the 258. I have read, watched a few videos, and asked one of my buddies in Kansas City who’s a jeep nut.
I will take some photos as I pull it all out and give an update. Was going to do it today but have to head to a paper mill to fix a flow instrument so they can get a boiler on line.

[67C10Step]

Well, this is the pile after I got down to the crank. Not overly tough, just takes time. I have determined it needs motor mounts, too. Has the wrong skid plate for this transmission as well. I'll fix it all up right when it goes back together.

[67C10Step]

New flywheel, clutch, pressure plate, and pilot bearing installed this weekend. As I suspected, the pilot bearing was incorrect and oversized for three speed T150 transmission. The input shaft was probably wiggling around with the old one. Working on cleaning up the bell housing and waiting on gaskets to seal up the transmission after inspection. Had to make some 1/4” diameter shifter pivot pins as one was missing and the other pretty worn.
Blasted and painted the shield and inspection covers as well. Waiting on the correct skid plate and transmission mount to arrive as well. Started scrubbing the drive shafts for paint and installing new u joints.

[Willowrun]

Wow, nice work!

[67C10Step]

Received the correct skid plate/transmission mount. Will clean up and paint this weekend. Got new motor mounts, transmission mount, and transmission gaskets on order. While waiting I decided to clean up the drive shafts, paint, and install new u joints. Cleaned up the bell housing and installed the new throw out bearing. Waiting on the new clutch fork boot to arrive and then it's going in.
Once I get the new motor mounts/transmission mounts installed I will install the new clutch bell crank and pieces.

[67C10Step]

Got this all put back in over the weekend. Good news, the backup light switch works. Bad news, found a broken motor mount bracket on the passenger side and the correct transmission mount will not clear the cobbled up exhaust system. So, my next step will be to cut out all the junk exhaust to get the transmission and transfer case mounted correctly. Then pull the motor mount bracket for repair.

"Wow, it's in better shape than I thought" was never said by a used jeep owner.

[FleetsidePaul]

Reminds me of my ole CJ5. Cool Jeep.

This was mine. It had the 258 inline in it. It took that hill across from me with no sweat. Never failed me.

Somebody wanted it more than me and offered me a lot of money so I sold it. Probably shouldn't have.

[67C10Step]

Paul,
I hope someone with more money than sense runs across me and wants this CJ when I’m done. I’ll drive it until then.
Got the transmission and all back in. Let the wife crown it off with the new shift knob.

[mongocanfly]

If you find "more money than sense" guy...send him my way..!!!!.. haha

[67C10Step]

Originally Posted by mongocanfly

If you find "more money than sense" guy...send him my way..!!!!.. haha

Right now I think I am that guy for getting another project started. And it's not that I have a lot of money, I just have less sense.

My biggest issue is I can put up with rust and less than perfect body but when it comes to the functional stuff I have to fix it correct or better than factory. This jeep just needs dozens of little things corrected. Then I'll tackle the looks department.

[67C10Step]

Been a slow go with all my other side track projects but I have the transfer case ready to go back in. Rebuilt the single stick linkage and got the majority of the slack out of it. Hope to get this and the drive shafts back in this weekend.

[Willowrun]

Looking good!
So how is the body on the jeep?

[67C10Step]

Body is ok, no real damage other than passenger side front fender needs a little work. Rust wise I guess it’s average. Both front floor pans will need replacing as well as one spot on the drivers side that is rusted through. It has been repainted once and done very poorly.

My plan is to build an off road jeep, not a street jeep. Therefore, my skill level of bodywork and paint is probably good enough. Definitely better than whomever was working on it before.

[67C10Step]

Driveline is all back in and full of gear oil. Ignition switch does not work in the START position so I have a push button wired in under the hood. Pulled the plugs and turned the engine over with the starter a few times to make sure all was well. Plugs show the engine to be running rich so I’ll clean them up and put them back in.
The under hood wiring is a mess so I am going to temp in power to the coil and ignition box tomorrow. Have disconnected the fuel tank from the pump so my plan is to bottle feed it and get it running. After that I’ll run through the entire fuel system.
So much to work out but one thing at a time.

[67C10Step]

Got us a runner it looks like. Installed a new fuel pump and plumbed up a 2 gallon jug to see if this thing would fire. After fighting the new fuel pump to get it primed I hot wired the ignition and she fired up without much trouble. Was able to run the engine long enough to get the thermostat to open and circulate some liquid. Now moving on to pulling the fuel tank to clean it up and the supply and return lines.
Working on pulling the dash as well. Need to work on the clutch/brake pedals. The jeep was originally a hydraulic clutch setup and someone in the past converted it to linkage and done it very poorly. While not as good as hydraulic, I am totally rebuilding the linkage clutch system, which includes a different clutch pedal. Already installed new bell crank and associated pieces.
Got an oil leak in my newly installed transfer case. Thought I got all the inspection cover bolts sealed up but I hope it's just one of those.

[67C10Step]

After getting the running gear back installed and then getting the engine running I started making a list of things I wanted to do mechanical and body wise. Got the fuel tank out, cleaned, new fuel sending unit installed, skid plate painted, and ready to go back in. Decided to wait to finish the exhaust.

Last weekend I went through my list and made an executive decision. The only way to get this rig the way I want it was to get the body off. So here we go, hope to have it all stripped down with the body off by the end of February.