Segment:
Light utility vehicle, off-road focused.
Contemporaries:
Competed with other compact 4x4s and utility vehicles of its era, but Jeep held a dominant position in the segment.
Vehicle Identity:
The CJ-5A represented a continuation of the iconic Jeep CJ line, known for its ruggedness, off-road capability, and utilitarian design.
Manual Value:
This factory service manual is an indispensable tool for owners and mechanics seeking to maintain, repair, and restore the Jeep CJ-5A to its original specifications.
Engine:
Detailed diagnostic, repair, and overhaul procedures for all applicable engine variants, including specifications, torque values, and timing adjustments.
Transmission:
Service information for manual transmissions (e.g., T-90, T-98) and potentially available automatic transmissions, including component disassembly, inspection, and reassembly.
Drivetrain:
Coverage of front and rear axles, differentials, driveshafts, and transfer case (e.g., Dana 20), including maintenance, repair, and adjustment procedures.
Suspension:
Detailed instructions for front and rear suspension components, including springs, shock absorbers, bushings, and steering linkage, with alignment specifications.
Brakes:
Comprehensive coverage of the hydraulic brake system, including master cylinder, wheel cylinders, brake drums, shoes, and lines; likely includes adjustment and bleeding procedures.
Steering:
Service information for the steering box, tie rods, drag link, and steering column, including adjustments and common wear points.
Electrical System:
Detailed wiring diagrams, troubleshooting guides for ignition, charging system (generator/alternator), lighting, starting motor, and accessory circuits.
Fuel System:
Information on fuel tanks, lines, fuel pump, and carburetor (likely Solex, Carter, or Rochester) diagnosis and repair, including adjustments.
Cooling System:
Radiator, water pump, thermostat, and heater core service, including flush procedures and capacity specifications.
Exhaust System:
Specifications and repair guidance for exhaust manifolds, pipes, and mufflers.
Body And Frame:
Information on body panel repair, chassis integrity, door mechanisms, seats, and windshield wiper systems.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tune-up procedures, and fluid level checks.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon faults across all vehicle systems.
Component Repair:
Step-by-step instructions for disassembling, inspecting, repairing, and reassembling individual components and sub-assemblies.
Overhaul Rebuild:
Detailed procedures for complete engine, transmission, and axle overhauls, including parts replacement and critical tolerance specifications.
Specifications Data:
Torque specifications, clearances, timing settings, fluid capacities, and other critical technical data for accurate repairs.
Wiring Diagrams:
Complete and detailed electrical schematics for all vehicle circuits, crucial for electrical diagnostics and repairs.
Depth:
Comprehensive, covering everything from basic tune-ups and fluid changes to full engine, transmission, and axle rebuilds, as well as in-depth electrical system troubleshooting.
Engine Type:
Inline 4-cylinder and Inline 6-cylinder gasoline engines were common in CJ-5 variants during this period.
Displacement 4Cyl:
Likely the Hurricane F-Head I4 (2.2L / 132 cu in).
Displacement 6Cyl:
Likely the Dauntless V6 (3.7L / 225 cu in) introduced later in the period, or earlier inline-6 options.
Horsepower 4Cyl:
Hurricane F-Head: Approx. 75-85 HP.
Torque 4Cyl:
Hurricane F-Head: Approx. 115-125 lb-ft.
Horsepower 6Cyl:
Dauntless V6: Approx. 155 HP.
Torque 6Cyl:
Dauntless V6: Approx. 225 lb-ft.
Carburetor:
Single-barrel carburetor, commonly Solex, Carter, or Rochester models depending on the specific engine and year.
Wheelbase:
Typically 81 inches (2057 mm).
Overall Length:
Approximately 133 inches (3378 mm).
Overall Width:
Approximately 63 inches (1600 mm).
Overall Height:
Approximately 64 inches (1626 mm) (with top).
Curb Weight:
Around 2,500 - 3,000 lbs (1134 - 1361 kg) depending on configuration.
Gross Vehicle Weight Rating:
Typically around 4,000 lbs (1814 kg).
Oil Change Interval:
Typically every 3,000-4,000 miles or 3-6 months, depending on usage severity.
Tune Up Interval:
Spark plugs, points, and condenser typically recommended every 10,000-12,000 miles.
Lubrication Points:
Regular chassis lubrication at grease fittings (ball joints, tie rod ends, steering knuckles, etc.) every 1,000-2,000 miles.
Engine Oil:
API SF/SG, SAE 30W or 10W-30 (depending on climate). Capacity: Approx. 5 quarts with filter for 6-cyl, 4 quarts for 4-cyl.
Transmission Fluid Manual:
GL-4 gear oil, SAE 90W.
Transfer Case Fluid:
GL-4 gear oil, SAE 90W.
Differential Fluid:
GL-4 or GL-5 gear oil, SAE 90W or 80W-90. Capacity varies by axle, typically 2-3 pints per axle.
Coolant:
Ethylene glycol coolant (50/50 mix with distilled water). Capacity: Approx. 12-15 quarts.
Common Wear Items:
Leaf spring bushings, U-joints, clutch components, brake shoes/cylinders, and exhaust system.
Electrical Faults:
Degraded wiring insulation, generator/regulator issues, and intermittent switch failures are common due to age.
Engine Issues:
Oil leaks, carburetor maladjustment, and occasional overheating can occur.
Jeep Legacy:
The Jeep brand has a storied history dating back to World War II, recognized globally for its rugged, go-anywhere capability.
Cj Lineage:
The CJ-5 was an evolution of the original Willys CJ series, introduced in 1954 and produced with various updates until 1983. The 'A' designation often indicated specific updates or package configurations.
Manufacturing Plant:
Jeeps of this era were primarily manufactured in Toledo, Ohio, USA.
Production Era:
The CJ-5 model ran from 1954 to 1983, with the CJ-5A specifically covering the years 1964-1968, representing a mid-cycle update period.
