CJ3A Operation and Care
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1. Crankshaft 2. Clutch Shaft Bearing 3. Flywheel Ring Gear 4. Clutch Facings 5. Clutch Pressure Plate 6. Clutch Pressure Plate Bracket 7. Clutch Release Bearing 8. Clutch Release Bearing Spring 9. Transmission Main Drive Gear Bearing Retainer 10. Transmission Main Drive Gear Bearing 11. Clutch Driven Plate and Hub 12. Clutch Pressure Spring 13. Clutch Adjusting Screw 14. Clutch Lever 15. Clutch Release Bearing Carrier 16. Clutch Control Lever Fulcrum 17. Clutch Control Lever 18. Transmission Main Drive Gear |
1. Main Drive Gear 2. Main Drive Gear Bearing Retainer 3. Main Drive Gear Bearing Retainer Oil Seal 4. Main Drive Gear Snap Ring 5. Main Drive Gear Bearing Snap Ring 6. Main Drive Gear Bearing 7. Synchronizer Shifting Plate 8. Shift Rail Cap 9. Shift Rail -- High and Intermediate 10. Shift Rail Poppet Ball 11. Shift Rail Poppet Spring 12. Shift Fork -- High and Intermediate 13. Control Housing 14. Contol lever Support Spring 15. Control Lever Housing Pin 16. Control Lever Fulcrum Ball 17. Gear Shift Lever 18. Shift Fork -- Low and Reverse 19. Sliding Gear -- Low and Reverse 20. Main Shaft Bearing Adapter 21. Main Shaft Bearing 22. Main Shaft Washer 23. Main Shaft Nut |
24. Main Shaft 25. Idler and Countershaft Lock Plate 26. Countershaft Gear Bearing Rollers 27. Countershaft Thrust Washer Rear -- Steel 28. Countershaft 29. Countershaft Thrust Washer Rear -- Bronze 30. Countershaft Gears 31. Transmission Case 32. Main Shaft Second Speed Gear 33. Crankshaft Bearing Spacer 34. Synchronizer Blocking Ring 35. Countershaft Thrust Washer Front -- Bronze 36. Countershaft Bearing Washer 37. Intermediate and High Speed Clutch Sleeve 38. Intermediate and High Clutch Hub 39. Synchronizer Ring 40. intermediate and High Clutch Hub Snap Ring 41. Main Shaft Pilot Bearing Roller |
TRANSMISSION ASSEMBLY
The transmission is a heavy duty, three speed synchromesh type unit with cane
type shift. It is attached to the rear face of the flywheel bell housing and is
supported on a rubber insulator at the frame centre cross member wich forms the
rear engine support. Shift is smooth and positive through a cane type control
lever mounted in a shift housing at the top of the assembly. Poppet balls and
springs retain the gears in mesh and an interlock prevents shifting into two
gears at one time. Should any trouble be experienced with the transmission
assembly, consult your Willys-Overland Dealer.
TRANSFER CASE ASSEMBLY
The transfer case Fig. 23 is an auxiliary unit located at the rear of the
transmission. It is essentially a two speed transmission, which provides a low
and direct gear, also a means of connecting the drive to the front axle. The
shifting mechanism is located on the transfer case for engaging and disengaging
the drive to the front axle, also for shifting the gears.
1. Output Shaft Oil Seal 2. Speedometer Driven Pinion 3. Output Shaft Bearing Shims 4. Intermediate Shaft 5. Intermediate Gear Thrust Washer 6. Intermediate Gear 7. Main Shaft Gar 8. Intermediate Gear Bearing 9. Output Shaft Clutch Gear 10. Output Clutch Shaft Pilot Bushing. 11. Companion Flange Assembly – Front 12. Output Clutch Shaft 13. Output Clutch Shaft Bearing 14. Output Clutch Shaft Bearing Snap Ring 15. Output Shaft Bearing Cap 16. Output Shaft Bearing Cone and Roller 17. Output Shaft Gear 18. Output Shaft Sliding Gear 19. Speedometer Drive Gear 20. Output Shaft |
On hard surface and level roads, disengage the front axle by placing the transfer case shift lever in the forward position. See Fig. 3 in GETTING STARTED. The right hand lever controls the gear ratio; low and high. The low gear can only be engaged when the left hand lever is in the engaged (rear) position for front drive. Proper position for disengaging axles to use the power take-off with the vehicle standing is shown as “N” in Fig. 3 in GETTING STARTED.
Both the transmission and the transfer case are precision built units. No external adjustments are possible and should attention be necessary, it is advisable to consult your Willys-Overland Dealer.
IMPORTANT: Check the units at each lubrication to guard against lubricant leakage. For economy the capacity is small – change the lubricant in accordance with instructions in GENERAL LUBRICATION.
PROPELLER SHAFT
The drive from the transfer case to the front and rear axles is completed
through two propeller shafts each equipped with two universal joints. The
splined slip joints at the transfer case end of each shaft allows for variations
in distance between the transfer case and the axles, due to spring action.
Examine both propeller shafts periodically for foreign matter which may become wrapped around them. Check for dents or a bent shaft and make sure that the universal joints attaching bolts are tight at all times. The universal joints have needle type bearings and are so designed that correct assembly is very simple. No hand fitting or special tools are required. The journal trunnions and needle bearing assemblies are the only parts subject to wear, and when it becomes necessary to replace these parts, the propeller shafts should be removed from the vehicle to facilitate replacement.
When reinstalling, note that the slip joints are marked with arrows, Fig. 24, at the spline and the sleeve yoke. Align the arrows so the yokes of the universal joints at the front and rear of each shaft are in the same plane, when assembled, to avoid vibration. The "U" type attaching bolt nuts should be tightened evenly with approximately the same pressure on each nut.
FRONT AXLE
The front axle is a live driving unit with hypoid drive gears, Fig. 26, and
spherical steering knuckles, Fig. 25, containing constant velocity type axle
shaft universal joints.
1. Cap, Wheel Hub -- Left or Right 2. Cap Screw 3. Shim Pack, Adjusting, Front Axle Universal Joint 4. Cone and Rollers, Wheel Bearings 5. Spindle, Front Wheel 6. Brake Drum 7. Brake Cylinder Assembly -- Front 8. Plate, Backing, Front and Rear Brake Assembly 9. Cup, King Pin Bearing 10. Nut 11. Pin, King 12. Cone and Rollers, King Pin Bearings |
13. Oil Seal, Steering Knuckle, Assembly 14. Universal Joint Assembly, Front Axle 15. Bushing, Axle Shaft, Front 16. Shim Pack, Adjusting, King Pin Bearing -- Top or Bottom 17. Pin, Lock, King Pin 18. Pin, Brake Shoe Anchor 19. Brake Shoe and Lining -- Front 20. Oil Seal Assembly, Hub 21. Wheel Hub Bolt Nut -- L.H. and R.H. Thread 22. Cup, Wheel Bearing -- Inner or Outer -- Front and Rear 23. Nut, Axle Shaft |
1. Hypoid Bevel Drive Gear and Pinion Set (Matched)
2. Drive Pinion Oil Seal 3. Universal Joint End Yoke Assembly 4. Drive Pinion Nut 5. Pinion Shaft Bearing Cone and Rollers (Outer) 6. Pinion Shaft Bearing Cup 7. Pinion Bearing Adjusting Shims (Front and Rear) 8. Drive Pinion Bearing Cone and Rollers (Rear) 9. Drive Pinion Bearing Cup (Rear) 10. Differential Bevel Pinion Mate Shaft Lock Pin 11. Differential Adjusting Shims 12. Differential Bearing Cone and Rollers. 13. Differential Bearing Cup |
14. Oil Seal Differential End 15. Axle Shaft (Left) 16. Gear Cover Screw Lockwasher 17. Gear Cover Screw 18. Differential Bevel Side Gear 19. Differential Pinion Mate 20. Differential Bevel Pinion Mate Shaft 21. Gear Carrier Cover 22. Differential Case 23. Gear Carrier Cover Gasket 24. Axle Shaft (Right) 25. Hypoid Bevel Drive Gear Screw 26. Drive Gear Screw Locking Strap |
The differential is mounted in a housing similar to that used in the rear axle, except that the drive pinion shaft is toward the rear of the front and to the right of the centre of the axle. This design allows placing the front propeller shaft along the right side of the engine oil pan without reducing the road clearance under the engine. The axle is of the full floating type and the axle shafts can be removed without dismantling the steering knuckles.
Once each year have your Willys-Overland Dealer remove the front axle universal joint and shaft assemblies to thoroughly wash out the steering knuckle housings and check the shim adjustment of the universal joints. After checking, the universal joint housings must be refilled with good quality lubricant as specified in the LUBRICATION section.
The lubricant is retained in the steering knuckle housings by felt oil seals mounted in twin retainers attached to the inner face of the housings, Fig. 5 in the GETTING STARTED section. These seals also prevent dirt and grit entering the housings. Inspect the seals regularly and replace them promptly if damaged.
Keep the spring loaded air vent or breather, mounted in the center housing cover, free of dirt at all times.
REAR AXLE
The rear axle is the semi-floating type, Fig. 27. End float of the axle shafts
is adjusted by the shims placed between the brake backing plate and the axle
flange.
To remove a shaft for reshimming or replacement, first remove the hub cap and
bend back the tongues on the shaft lock nut. Use a wheel puller to remove the
wheel hub. Remove the bolts holding the brake dust shield, the grease and
bearing retainer and the brake assembly. Also remove the shield and retainer.
Pull out the shaft, using care not to lose the bearing adjustment shims. Should
the end of a broken shaft be inside the axle housing tube, the broken end can
usually be removed by making a loop in a piece of wire and working the loop over
the end of the shaft using the wire to pull it from the housing. When the shaft
is replaced, adjust the bearing with the shims to allow proper end play of the
shaft. See “Rear Wheel Bearings” in the SUSPENSION section.
1. Wheel Hub Cap,
Left or Right 2. Axle Shaft Nut 3. Wheel Hub 4. Brake Drum 5. Brake Cylinder Assembly, Rear 6. Backing Plate, Front and Rear Brake Assembly 7. Brake Cylinder Bleeder Screw 8. Brake Hose Connection 9. Axle Shaft Grease Retainer, Outer 10. Cone and Rollers, Axle Shaft Bearing 11. Axle Shaft, Left 12. Differential Bearing, Cone and Roller 13. Differential Bearing Adjusting Shims 14. Hypoid Bevel Drive Gear and Pinion Set (Matched) 15. Pinion Bearing Positioning Shims 16. Pinion Bearing Cone Shims 17. Drive Pinion Oil Seal 18. Universal End Yoke Assembly 19. Drive Pinion Bearing Oil Slinger 20. Drive Pinion Bearing Cone and Roller, Front |
21. Drive Pinion
Bearing Cup, Front 22. Drive Pinion Bearing Cup, Rear 23. Drive Pinion Bearing Cone and Rollers, Rear 24. Differential Bevel Pinion Mate Shaft Lock Pin 25.Axle Shaft, Right 26. Differential Bevel Side Gear 27. Differential Oil Filler Plug 28. Differential Bevel Pinion Mate 29. Differential Bevel Pinion Mate Shaft 30. Hypoid Bevel Drive Gear Screw 31. Drive Gear Screw Locking Strap 32. Differential Centre Block 33. Differential Bearing Cup 34. Differential Gear Carrier Cover Gasket 35. Axle Shaft Grease Retainer, Inner 36. Axle Shaft Bearing Grease Connection 37. Axle Shaft Bearing, Cone and Roller 38. Differential Bearing Shims 39. Brake Shoe Anchor Pin 40 Brake Shoe and Lining Assembly |
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