Diesel CJ5 Rebuild

Here are a few pics of where I'm at now. I've been getting a lot done despite the cold. I don't have a heated garage but after a few hours my 1000 watt work lights make the fairly pleasant to work in there.

The rebuilt T90 and D18.


The T-case, O/D and PTO.


The Ramsey DP-1 sticks installed.


-Dean

 

hmm sounds like time to customize a turbo set up. after cooler, propane injection. oh i'm sorry dreaming at keyboard. nice project.

 

That thing is kick arse!!!!

 

Nice work :drool:

 

good job ! is a 4192 perkins ?

 

Thanks guys. I'm really close to taking a first test drive. And yes, its a factory 4.192 perkins.

-Dean

 

Very cool project, keep up the good work!

 

Very nice!
I'd love to see dyno spec's . . .

Does anyone have the original Jeep specs ?

 

I was back in NY for the holiday weekend so I didn't make any progress on the jeep. This coming weekend is looking promising as I have no plans other than to hang out in the garage and finish this thing.

Here are the only engine specs I have found for the 192 perkins...

Perkins 192 4 Cylinder
Bore x Stroke 3.50" x 5.00"
Displacement 192.2 ci(3.15L)
Compression Ratio 16.5:1
Horsepower (gross) 62@3000rpm
Torque (gross) 143@1350
Main Bearings 3
Valve Configuration OHV


-Dean

 

What a cool rig.

I think you're ahead in the shifter count contest.

Is it six shifters? That's impressive.

The two shifters for the PTO - one is a neutral/drive to the rear and the other is neutral/drive to the PTO? I'm just guessing.

 

Yeah, it’s got six shifters. I can’t wait to use them all.

It’s also got two twist locks on the dash and a few other control knobs unique to the diesel engine.

The right shifter (if you’re sitting in the driver’s seat) has 2 positions and engages the PTO unit when you pull it up.
The shifter to the left has 3 positions. All the way forward engages the rear PTO output which is centered. All the way back engages the front PTO which is offset to the driver’s side. Neutral is in the center and there is no way to engage both the front and rear PTOs at the same time.

I’m still not sure what to use the PTOs for. I have an old Belleview winch I was going to mount on the front instead of a PTO winch so I was thinking of a running a PTO driven air compressor and generator.

-Dean

 

Nice jeep get to work springs coming..

 

As I'm getting closer to driving this thing I realized I've never had the locking gas cap off. The jeep only came with one key and I was skeptical that it would work but much to my delight it unlocked the gas cap.

Were locking gas caps a factory option or did someone just file the tumblers in this one to make them work with the ignition key? Or I guess a third option is that its a crappy lock and anything will open it.

Not much of an update to offer. I have gotten a little more done...

The clutch linkage and the ebrake assembly are installed. Drivetrain is all lubed up. I still need to install one rear wheel cylinder, 2 rear brake lines and a set of tail lights.

Is there any break in recommended for a rebuilt trans/t-case? Maybe some low speed, low load driving to get things seated correctly?

Thanks,
-Dean

 

It was 60 degrees here in Boston yesterday so I left work early to do some work on the 5. The goal was to get the front axle completely back together.

I finished installing the knuckle seals and whipped up my first batch of knuckle pudding which my fiancé got a real kick out of. I still haven't decided how to get it in the knuckle. I have a big grease gun that’s empty so I think ill try to pump it in the knuckle with that.

Then I drained the differential to replace the leaky gasket. The cover still had 4 tags attached to it which is pretty neat...


And once I got the cover off I could confirm what I hoped was true. I've got a PowrLok in the front axle...


I got the diff all sealed up. All that remains to do on the front end is load the knuckles with pudding and bleed the brakes.

-Dean

 

That'd be my guess. Never heard of a locking gas cap option. I bought a 78 Cherokee once from a guy who was friends with a locksmith. He had his friend key every door, ignition, tailgate and glovebox lock with the same key. So I don't think it's that hard for them to do.

 

Hey, I used to have a rig just like that one!!!.

Pictures look great!

uj.

 

BTW, that locking cap is aftermarket. It also leaks if you overfill the tank.

Concerning the rear tanks, after you transfer fuel to the main tank, you have to shut off the transfer valve by the tailgate. If the rear tanks are full and you leave that valve open, fuel will continue to flow (downhill) to the main tank and over-fill it. A spring loaded check-valve added to the circuit would likely eliminate that possibility.

 

Nothing new to report but it was nice out this morning so I pushed the 5 into the driveway and took a few pictures of it with the new tires and wheels. The tires are 30x9.50. I had wanted to go with 31s but I'm quite pleased with the way these look.

-Dean

 

She Lives!!!

Thumbs-up!

 

Looking good!