🏷️ Basic Information

Make:

Jeep

Model:

CJ-5

Year:

1963

Chassis Code:

CJ-5 (CJ-5 Series)

Manual Product Name:

Jeep CJ-5 1963 Service Repair Workshop Manual

👋 Introduction

Historical Context:

The CJ-5 represents a pivotal point in Jeep's utilitarian off-road legacy, evolving from its military roots into a civilian icon. This 1963 model showcases the robust design that defined the CJ series for decades.

Era Comparison:

Competed against other light utility vehicles and early SUVs, but its focused off-road capability and rugged simplicity gave it a unique market niche.

Vehicle Appeal:

Renowned for its go-anywhere capability, iconic styling, and straightforward mechanicals, making it a popular choice for off-road enthusiasts and utility work.

Utility For Owner:

Essential resource for maintaining and repairing the classic Jeep CJ-5, ensuring its longevity and original performance characteristics. Crucial for collectors and restorers.

📋 Manual Details

General Coverage:

Full service, repair, maintenance, troubleshooting, and diagnostics.

Specific Systems:

Engine, fuel system, cooling system, exhaust system, clutch, transmission, transfer case, drivetrain, axles, steering, brakes, suspension, electrical system, body, chassis, interior, and accessories.

Estimated Pages:

700+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (Likely PDF), Printable

📖 Manual Coverage

Engine Mechanical:

Detailed breakdown and overhaul procedures for the Hurricane F-Head I-4 engine, including cylinder head, block, crankshaft, connecting rods, pistons, camshaft, valve train, lubrication system, and cooling system.

Fuel System:

Carburetor adjustment and overhaul (likely Carter WCFB or similar), fuel pump, fuel lines, and fuel tank servicing.

Transmission Drivetrain:

Service for the T90 3-speed manual transmission, Dana 18 transfer case, front and rear axles (likely Spicer Model 25 or Dana 44 variants), driveshafts, U-joints, and wheel bearings.

Electrical System:

Wiring diagrams, ignition system troubleshooting and repair (distributor, coil, spark plugs), starting system, charging system (generator and regulator), lighting, instrumentation, and accessories.

Brakes Steering Suspension:

Hydraulic drum brake system overhaul, master cylinder, wheel cylinders, brake shoes, brake lines. Steering gear box adjustment and repair, tie rods, steering linkage. Front and rear leaf spring suspension, shock absorbers, bushings.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, tune-up procedures, lubrication points, fluid checks and changes.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues across all major vehicle systems.

Repair Overhaul:

Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components and systems.

Specifications Data:

Torque specifications, clearances, fluid capacities, timing settings, electrical specifications, and more.

Depth Level:

Comprehensive, covering everything from basic maintenance to complete engine and drivetrain rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format), typically optimized for searchability and readability on computers and tablets.

Printability:

Designed to be printed for workshop use. High-resolution diagrams and text.

Physical Format Equivalent:

If printed, would be a sturdy, spiral-bound or comb-bound manual for easy page laying.

Physical Format Equivalent Paper:

Durable, matte finish paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Model:

Hurricane (F-Head Inline-4)

Engine Displacement:

220.7 cu in (3.6 Liters)

Bore X Stroke:

3.4375 in x 4.00 in

Compression Ratio:

6.8:1 (typical)

Horsepower Net:

Approx. 75 HP @ 3600 RPM

Torque Net:

Approx. 120 lb-ft @ 1600 RPM

Carburetor:

Single barrel, typically Carter WCFB or similar downdraft carburetor.

Fuel Type:

Unleaded gasoline (octane rating appropriate for era)

Ignition Type:

Distributor, Coil, Spark Plugs

Cooling Type:

Water Cooled, Thermostatically Controlled

🔧 Transmission

Transmission Type:

T90 3-Speed Manual Synchromesh

Overdrive Option:

No factory overdrive option widely available for 1963 CJ-5, direct drive focus.

Transfer Case:

Dana 18 two-speed transfer case with constant 4WD or selectable 2WD/4WD.

T90 First Gear:

2.82:1 (approx.)

T90 Second Gear:

1.57:1 (approx.)

T90 Third Gear:

1.00:1 (approx.)

Dana 18 Low Range:

2.46:1 (approx.)

Transmission Fluid:

GL-4 Gear Lubricant, SAE 80W or 90W (verify specific manual recommendation).

Transfer Case Fluid:

GL-4 Gear Lubricant, SAE 80W or 90W (verify specific manual recommendation).

📐 Dimensions

Wheelbase:

81 inches (2057 mm)

Length:

130 inches (3302 mm) (approx., varies with body style)

Width:

64 inches (1626 mm) (approx., excluding fenders)

Height:

60 inches (1524 mm) (approx., to top of windshield frame)

Curb Weight:

2500 - 2800 lbs (approx.)

Payload Capacity:

Approx. 700-1000 lbs

Towing Capacity:

Typically 2000-3500 lbs (verify specific configuration)

Standard Tire Size:

6.50-16 (typical, bias-ply)

Wheel Bolt Pattern:

5 on 5.5 inches (139.7 mm)

Wheel Size:

16 x 5.5 inches (steel wheels)

🛡️ Safety Features

Crash Test Data:

No formal crash test ratings as per modern standards for this era.

Braking System:

Hydraulic drum brakes on all four wheels. Manual parking brake.

Steering System:

Recirculating ball steering gear (manual).

Seat Belts:

Optional or not standard equipment depending on specific vehicle configuration and region.

Rollover Protection:

Basic windshield frame and minimal structural support. Roll bar not standard.

💡 Technology Features

Audio System:

Basic AM radio (optional), manual tuning, often with single speaker.

Gauges Instruments:

Minimal dashboard instrumentation: speedometer, fuel gauge, oil pressure gauge, ammeter, temperature gauge. Warning lights for generator and oil pressure.

ABS:

Not applicable.

Traction Control:

Not applicable.

Bluetooth Usb:

Not applicable.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months (typical for the era, manual will specify exact mileage and conditions).

Tune Up Interval:

Every 12,000 - 15,000 miles, or annually (includes spark plugs, distributor points, timing adjustment).

Transmission Fluid Change:

Every 24,000 miles or 24 months (check manual for specific recommendations).

Rear Axle Fluid Change:

Every 24,000 miles or 24 months (check manual for specific recommendations).

Engine Oil:

API Service Classification SE or SD, SAE 10W-30 or 10W-40 (verify manual for exact viscosity and classification).

Engine Coolant:

50/50 mix of permanent antifreeze and water (typically ethylene glycol based).

Brake Fluid:

DOT 3 Hydraulic Brake Fluid.

Engine Oil Capacity:

5 Quarts (4.7 Liters) with filter change.

Cooling System Capacity:

Approx. 11 Quarts (10.4 Liters).

Transmission Capacity:

Approx. 4 Pints (1.9 Liters).

Transfer Case Capacity:

Approx. 4 Pints (1.9 Liters).

Engine Wear:

Oil consumption, valve stem seal wear, and potential for piston ring wear due to age and operating conditions.

Rust Corrosion:

Common body rust points include floor pans, rocker panels, fenders, and tailgate. Chassis rust is also a significant concern.

Electrical Gremlins:

Aging wiring harnesses, corroded connections, and failing switches can lead to intermittent electrical issues.

Suspension Bushings:

Rubber bushings for leaf springs and shackles degrade over time, leading to a softer ride and potential handling issues.

📚 Vehicle History

Jeep Legacy:

Jeep's lineage traces back to World War II military vehicles, establishing a reputation for ruggedness and off-road prowess.

Cj Series Context:

The CJ-5 was introduced in 1954 as a civilian successor to the Willys Jeep, and the 1963 model year represents a period of refinement and adaptation of this iconic platform.

Engine Introduction:

The Hurricane engine was a key development for Jeep's civilian line in this era, providing a balance of utility and performance.

Manufacturing Location:

Toledo, Ohio, USA (Willys Motors / Kaiser Jeep Corporation)

Production Period:

The CJ-5 was produced from 1954 to 1983, with the 1963 model being a significant iteration within that long run.

🏆 Awards & Recognition

Off Road Icon:

Consistently recognized as an iconic off-road vehicle and a significant part of automotive history.

Restoration Community:

Highly regarded within the classic Jeep and off-road restoration communities for its robust construction and abundant aftermarket support.

Historical Vehicle Status:

Qualifies for historical vehicle registration and associated benefits in many regions due to its age and classic status.