Jeepers 81 CJ5 rebuild

jeeper4life

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So I picked up this 1981 CJ5, I think its in pretty decent shape. The body has rust here and there. The frame seems good. The motor is a 258, believe the trans to be the T176, and a D300 for a t-case. Dana 30 front and AMC 20 rear. Have no idea what gears are in it, still need to find that out. The 258 knocks i'm told, I haven't tried to start it and listen to it. I believe barrie lol. Plans right now are to get it running, fix the suspension issues, make the brakes stop and do a fluid fest on it. Then drive it around the street, and slowly make it "shine"

So here's some pictures of it at barrie's getting loaded up and ready to head north..
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Oh and here's where it sat for awhile..
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Here's it arriving at my place, dang indiana had to drop some snow on us.. this is the last time it will see snow..
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getting it unstrapped from the dolly
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unloaded and warming up in the garage next to the red jeep
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It came with some factory wheels that will go back on it
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Heres some over all pictures of it, still kinda frosty from the trip..
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Here's the motor
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Dana 300!
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frame seems decent..
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the dana 30, see its currently sprung over, I wanna get new stock springs and shocks, and put it back to spring under..Also take the crazy big shackles off of it and put stock ones back on..
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Amc 20..
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the bed area
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I had my pug check for rodents
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Playing around with the fold down windshield.. lol
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the front drivers seat looked to be out of an f150 and its cloth. it was all moldy and stinking up the garage, so out it came! however I had to cut it out because the nut in the tub was just spinning..
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yucky seat..
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thats pretty much it, I drained the oil in the motor, it seemed decent. I was gonna pull the oil pan and peak around but haven't yet. I pulled two of the spark plugs and they seemed in really good shape. So I'm hoping the motor is still in somewhat decent shape for the rebuild. This is gonna be a slow thread of fixing it up, so you may get bored!
 

jeeper4life

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Only thing I have really picked up for it is a new set of shift knobs.. boring I know lol
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I charged the battery up, well the most it would hold a charge, turned on the lights and not all work.. will have to look into it, electrical is not my strong point
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noticed the radiator was dry and started filling it up, found out the heater box leaks..
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While messing around under it, I noticed someone removed the trans mount bolts..
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I found one in the back of the tub that seem to fit.. need to find another one.. but at least it makes everything more solid for the time being..
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and is this supposed to be open like this?
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Was doing some searching into the factory paint color.. gonna go with dark brown..(the photo kinda makes it look maroon but its really brown)
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and I finally got around rolling it out and getting it soaped up and hosed off..my son helped move it out..
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and my wife had WAY to much fun helping push it back in the garage..
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and last but not least.. seems like a happy driveway/ garage right? lol
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jeeper4life

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Well did a oil change on the motor, just because I didn't know what was in it and I'm guessing it was old. The plan was to try and get it to start. Also picked up some primer and paint for when I pull the front axle to redo the suspension on it and bring it back to spring under.
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So charged up the battery...and nothing. Starter just makes a slight grinding noise.. I feared the motor was stuck/ locked up. I removed the fan belt and was able to turn the motor over by hand fairly easily. So now back to figuring out how to get it to fire.
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Which it got late and I just fiddled with other stuff..
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but I did get the rear lights working.. So it wasn't a total fail
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The next day the cops came. and checked it out.. and deemed it safe to sit in my garage!
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jeeper4life

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So I have fallen a bit behind on updating this.. I have gotten some stuff done to it here and there. Nothing major but stuff it needed really.
Its kinda been a fancy storage bin..
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and a play pin for my son..
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here's a few items I have picked up for it.
A new glove box
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A summer top..
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new (to me) windshield brackets for when I put the correct windshield back on it
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a set of factory repop shackles
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and in my stash of jeep crap, I found this! hey better than nothing..
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Also was looking into fitting a YJ back seat into it, its a seat out of my old YJ, which I miss and this thing kinda reminds me of. So kinda for weird sentimental reasons too
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What its legit?
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and I have seemed to of miss placed some pictures somewhere but I ripped the front axle out and got it cleaned up..
Primed up
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and painted up..
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Painting the underside..
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and how I moved it around, Cj dana 30's are heavy! compared to the TJ/XJ dana 30's of today..
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Cleaned up the gasket surfaces..
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Shiny!
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and with the help of my son, I got that pig back under the jeep.
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I plan to replace the springs and shocks, but for now I just put everything back together to keep it mobile, incase I need the space for a bit.
the first time I have "lowered" a jeep in my life.. back to stock!
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I need to get the rear shackles on, but I plan to pull that axle and get it cleaned up also
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My dirty little helper!
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and tonight I pulled the diff cover and threw on some ultra gray and got it sealed up and ready for fresh gear oil
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Thats pretty much it for now, if I find those other pictures I will post those up..


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jeeper4life

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Ok here's a little update..

A couple weekends ago, my edition had their annual "everyone have a garage sale weekend" I sat in the CJ and "people" watched like an old man. However something funny happened with one shopper, It was a younger lady, in an MK, not bad looking. She goes to get back in her jeep stops, sees the TJ, see's the CJ, and then KJ.. then goes to get in her MK but stops again and looks at the driveway for a minute and then finally gets in and leaves. It was really weird. but she was hot so I didn't care..
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Anyway I picked up a hitch for the 5, and the guy threw in a YJ roll bar. lol I actually traded those crazy big shackles for the cj hitch..
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I already had the fronts removed because I cleaned the front axle all up.. so I had to scramble to remove the rears..

"look ma, no shackles!"
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and those that know me, know I hoard jeep parts of all sorts, well I don't have factory CJ shackles for the rear yet, well I have one but need another. so I found some factory YJ shackles and threw those on for the time being. just to keep it mobile if I need to move it in and out
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The YJ shackles are still a bit taller than CJ ones, so her butt's still up a little..
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My switches and knobs are finally here! a new wiper switch and heater swtich! the other three are cables, so I'm gonna pick those up soon to replace
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Then.. bored last night I said fawk it and did this..
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the AMC 20's new home for right now..
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and for some reason AMC thought it would be a good idea to make the diff cover bolts torx! Well three wouldn't come out :censored: So I very carefully cut the heads off but ruined the cover.. hey I would rather the cover than the housing! I'm thinking about picking it up a fancy cover but may just go with a new to me stock one
Saluting the torx bolts! they will be getting replaced with regular bolts
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and once inside, not as bad as I expected but the gear oil was still pretty bad! and boo no trac lock. Which I wasn't to surprised, the jeep seems like a base model anyway
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got the axle all wire wheeled, (yes the cover was on during the wire wheeling to protect the gears)
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and first coat of primer! note the untouched cover lol
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thats pretty much where I'm at, my garage is once again a wreck!


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jeeper4life

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oh yeah, I made up a list with everything I can think of at the moment, I'm sure it will only grow more! lol
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Also forgot to add, I have been browsing fleabay for my T176's missing inspection cover that got taken off by the previous owner and is long since gone..
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I was worried it wasn't gonna match up because someone said the T177 is similar but I think that trans was only used behind the 4 bangers.. either way it matches up.. just need to find bolts that fit
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jeeper4life

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Mainly just trying to sell stuff and save for an engine rebuild and doing cheap little stuff here and there.

I got the amc 20 all painted and back under the jeep
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and bam!
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Then added a factory radio delate plate,
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Then got a new set of dash indicators, installed them and got them working
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just a random figuring out what carb i have picture lol
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Then purchased a factory overflow tank to add factory heavy duty cooling
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and recently we have had a lot of rain
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so finally when it stopped I move the CJ to the other side of the garage with my red jeep and warn winch
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because it will make it easier to pull the engine when that time goes
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Also purchased some threaded rod and cut to size for my new shift knob
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thats pretty much it for now, until i can find other little things to do while I save.
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jeeper4life

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Ok its been forever since I have updated this so here it goes!

I got the t-case shift knob issue all worked out. AMC made two different kinds of D300 shift handles.. kinda annoying but a slight mod fixed the issue.
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and I has two new shift knobs now!
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The original owner also found the owners manual and paperwork and mailed them too me! i was excited!
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My son is working on his jeep too
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Just playing around, thinking about making a winch plate for it
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and put the TJ steering wheel and airbag on for laughs lol
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and maybe a rubi locker switch? lol
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Ok, ok enough playing around, here's where things start to get real! I found and got another CJ5.. a 1977, running and driving just really really rusty. well the tub that is. It is 95% original too.

It was currently living on a farm in southern ohio, here's some pictures
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a dang strong running 258
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oh and it had buddies
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It ran and drove, and had a clean title, so loaded it up and off it came to my driveway!
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The people next door loved it! another jeep! lol Here's a few more pictures of it at home
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My son loved it! another jeep to play in!
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dana 20
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warn premiums
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and it even came with extra parts!
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Some trail doors!
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a factory hitch
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It truly is a shame the tub was beyond rusty, it was so original. but it was time to take what I needed, so let it begin!
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first out! the back seat!
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and found a army shovel!
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sat the new to me back seat in the 81
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I was digging it!
so transferred over the factory fronts to the 81
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the interior is pretty much complete now..
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While the seats aren't brand new, it gives me something I didn't have, something to plant my butt in! and they are a factory..

Well now its time to get real, real my friends.. so the JK helped me haul this box home..
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What could it be you ask? My "motor ****"
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So lets get this on!
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and bam! instant room to work!
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and drove the 77 in.. it was time,
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and out came the 77's motor!
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Thats pretty much it on catching you guys up, this weekend I plan to order my gasket kit for the good motor, "AMC blue" paint for the motor, and some bolts to bolt it to my engine stand to work on it and get it ready to be placed in the 81. I need to get the "bad" engine pulled out of the 81 yet. I also need get the 77 torn down the rest of the way because I'm sure the people next door love seeing a half torn down rusty jeep sitting in the driveway lol


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jeeper4life

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Here's another update for those following along,
I pulled the bad motor out of the 81
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mounted the good motor to the stand
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Also picked up an old factory Jeep amc radio
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and then picked up a few items needed to overhaul the good motor and get it running tip top
The photo that caused large amounts of rage from many! :lol:
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some tune up items
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the 81's valve cover is made of plastic and cracked, 81 was the year that Jeep really focused on fuel milage. however the 77's is made of metal and an all around better design. Just needs cleaned up and painted.. back to AMC blue! so thats what I did
wire wheeling
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2 coats of engine primer
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and 2 coats of AMC blue
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However the 77's oil pan was rusty and nasty.. the 81's was not, so I pulled that and will clean that up, and swap that over to the good motor
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and it turns out the 77 has been quite the little gem, old aftermarket jeep stuff.. gonna reuse the center console
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breaking the frame and rear axle down off the 77 in true redneck style!
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and again the 77 strikes again.. come to find out the axles are better than whats in the 81.. better gears, bigger brakes, and warn premium hubs.. so.. gonna clean those up and swap those under the 81 also.
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Thats it for now, I need a new clutch which is currently stopping me from getting the good motor sitting in the frame rails of the 81, but I'm waiting until my wife goes back to work, so its not just my income to get one. For now I'm working on cleaning up the 77's axles.


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jeeper4life

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Alright so here's a little update on the 5,

I ended up having to deep six my axle swap project mainly because of this..
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The rear axle was ate up something crazy and I failed to see it before I started cleaning up the front axle. So I just pulled what I wanted off the front axle to swap over to my 81's clean axle
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Still have to pull the larger drum brakes off the rear axle. Not 100 percent sure I'm gonna mess with that though.
Anyway, as some of you know I got the motor in, but before that I added a new clutch, pilot bushing, and throw out bearing
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new pilot bearing in
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test fitting the new clutch
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Threw the new clutch on
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I pulled the trans and t-case for a couple of reasons, my t-case is leaking, I want to paint it up, along with the my belly pan, and I thought it would be easier to mate the trans to the engine that way.
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I then separated the two
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brought the t-case inside for kicks
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anyway, mated the trans and engine up and threw them in, here's a teaser shot
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I had pull the front bumper off to gain a little wiggle room, plus it got scratched, and I didn't like the glossy paint i put on it before. So I cleaned it back up and repainted it
before work
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bare
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first coat of primer
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added a second coat of primer and two coats of flat black, then threw it on!
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My seal and gasket kit showed up for my trans, I only replaced what was leaking and what was easily accessible.
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shifter cover
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Then got back to motor, tried throwing my manifolds back on but ran into this.. ugh..
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I drilled it out and got it on! I figure if it doesn't end up working, I will just buy a new one.
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Man that looks good doesn't it?
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Next will be buttoning up the motor, new plugs, cap, rotor, wires, water pump, and t-stat. After that, need to fix up my t-case, gonna do the belly pan also. I can't test fire the motor anyway until I get a radiator and heater core. However its getting there!


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jeeper4life

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Ok, have more to post but it's almost caught up. If things seem a little off its because most of this is copied and paste from another site, so I didn't have to retype it all.


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