67 Cj5 Build Thread By A Rookie

The aftermarket ignition I used was too small for the dashboard hole too. Looking forward to seeing how the washer works out.

 

More wiring today. I finished the harnesses to connect the gauges. I redid what I started yesterday because I wanted female spades instead of rings to make it easier to assemble.

12V switched to power gauges (red) comes from speedo to tach to oil to volt to temp (I’m not using the temp gauge on the cluster.
12V from light switch to instrument lights (brown) follows the same path to the white wires to the bulbs.
Ground (black) follows the same path across the instrument then loops up to join the black wires to the bulbs.

 

I found a 1” OD 3/4” ID nylon washer at the hardware store. Both were just a little tight, but I was able to thread the washer onto the ignition switch and then (I think) compress it into the hole in the dash. I will to check it out with the fiber optic camera and report back. It may need a little “machining!”

 

I spoke to my my mechanic (he’s a good dude, his dad has a baby blue CJ5 ) and he said they primed it with a drill and no leaks. I will keep a close eye when I start it up.

 

Ok, maybe everything is good to go, I am so cautious when other folks work on my vehicles ever sense my neighbor called one afternoon and said "the rear wheel came off my jeep (a 67 cj5) over in wildcat cove, wonder if I could get you to come with me and take a look at it." Well it turns out he had just had the jeep worked on for an oil leak at the rear wheel and the mechanic had accidently reinstalled (pressed on) the wheel bearing backward. why it did not come off in the first 10 or so miles before he got there is still a mystery. Oh, and if you can let us know what the break-in procedure for your new cam is when the time comes, and maybe a video if possible. .

 

I have not seen everything but this is a first on that gasket.

 

yep, I was wondering if it might have been a multiple/universal fit gasket of some sort for different models of oil pumps. . Hopefully It will work out ok.

 

I have not seen an extension on the transmission such as this

 

I don’t know the story on the extension. It is a SM-420 if that sheds light on anything.

 

I haven't been able to find anything on it. I wonder what it was for and more concerning is how it works.
That's gonna take a tall boot.

 

If I were guessing, this tall shift tower transmission was probably used in a larger/heavy truck where there was a lot of space between the top of the transmission and the floor of the cab.

 

It shifted fine before I took it apart. Is there something in particular you think I should be watching out for?

 

Just curious on how it works while knowing how a regular one works.

 

Is that not just a tall boot?

 

No tranny cover on yet.

 

I got the steering column in today. Everything comes with a lesson.

The steering column is a Flaming River 48 spline. The u joint is (I think) a Borgeson D-49 spline. I counted the threads to confirm! I had a tough time seating the steering column into the u joint, so I made the bad choice to give it a little nudge with a rubber mallet. I stopped after about 1/4” as it was apparent it wasn’t going to play nicely. The old column slid right in with ease.

I spoke to the Flaming River rep and he said that their columns tend to be on the high side of 1”. Sure enough, the new column was 1.02” and the old was .986”. About 30 minutes sanding (and 10 minutes using a knife file to fix the threads on the u joint), and I was in business. I mounted to column to the dash and then realized the edge of the dash pulled forward from the cowl, so off comes the column, drilled holes for the edge and corner of the dash, and more to come tomorrow!

 

Here is how I separated the steering column from the u joint after the rubber mallet fiasco. DIY u-joint pusher.

 

I think I screwed up my Jeepster clutch repair, so I decided to do some easy work on the CJ5 to make me feel better!

New face on the jeep:

Firewall pass through ground:

I also rerouted the rear wire harness and installed the fuel filler.

 

It is taking shape nicely.

 

Before
After
Good enough? This was by far the worst part of the radiator.