Build Thread 1972 CJ5 “re”build

[BMK84CJ572]

I recently bought my first CJ mostly as a deer lease vehicle. I’ve wanted one since I was a kid listening to stories my dad would tell about his (‘74 CJ5 with the AMC 304 V8). I knew it would need work eventually; It is much older than I am after all, but I wasn’t expecting it would be so soon!

While at the lease a couple of weekends ago I lost the ability to shift. After posting on here and getting some input from a few forum members, I decided to go ahead and drop the Transmission ; I would have to in order to fix the clutch anyway, and just do a thorough inspection of the Transmission and Transfer Case .

Well after getting it down yesterday it is clear that it needs some TLC. The seals are shot, the Transmission bearings are shot and it was getting water in somewhere or several somewheres! I ordered a rebuild kit for the Transmission (BW T-15 ) and Transfer Case (Dana 20 ) from Novak and I’ve started the tear down process.

I’m also going to replace the single shift stick for the Transfer Case , which was worn out and in need of replacement, with a double shift stick from JB custom fabrication. I just ordered replacement clutch parts from Rock Auto, not doing anything too fancy there, but I am upgrading to a diaphragm pressure plate.

A couple of other items I want to address: it seems like the folks who worked on this Jeep prior didn’t get things lined up as well as I would like, the Transmission was sitting so high that they couldn’t properly fasten down the floor plates because the bell housing was in the way, and the differentials, front and back, are tilted. I’m still not sure if that was because the u joints couldn’t accommodate the 2.5” lift from the replacement leaf springs or if they just did it because they wanted to, but I would like it if the dowels on the axle bracket for the leaf springs actually sat properly in the leaf springs. Right now they are shimmed and just bolted down tight to hold the angle. Is this a common thing to do?

In summary for this build I expect to (at a minimum): install a new clutch, rebuild the Transmission , rebuild the Transfer Case , install double stick shifter for the Transfer Case , fix alignment issues with the drivetrain, reset the axles, and who knows what else (haven’t even really dug into the engine yet)! Wish me luck!

Here are a few photos so far:









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[CJ]

Great build that is going on. You have a rock starting place.
You have experience so I can't wait to follow your progress.

 

[BMK84CJ572]

Update: 12/27/24

I've got the Transmission apart and waiting on the rebuild kit from Novak. Next I'll get started on the Transfer Case . There is some corrosion in the Transmission from water getting in, but the teeth on the gears look to be in pretty good shape which was good to see. From what I can tell the main issue was bad gaskets and seals (and shifter boot) letting water in and gear oil out. I'm also wondering if there were some missing roller bearings. I counted 21 shorter (main shaft) roller bearings and 44 of the longer thinner roller bearings. I think it was missing 1/3 of the thinner roller/needle bearings.

I've been looking for a countershaft as well. The existing shaft has some wear on it. I measured about .75492 inches in diameter on spots without wear and .75149 on the spots with wear. What I don't know is if the 3 thousandths difference really matters. I think I would like to replace it though. If anyone knows where I can source one in good shape please let me know. So far I've only found one on eBay and it had some corrosion on it. It looked like just a little surface rust, but I couldn't be sure there wasn't any pitting from the photos.

Here are some more photos of the Transmission broken down and the countershaft. You can see the wear (lighter shaded spots) on the shaft.

 

[CJ]

Dana 20 correct?

+16

Dana 20 Rebuild

• CJ
• Mar 16, 2009
• 25
• 2

Images from the Dana 20 Rebuild

 

[BMK84CJ572]

Dana 20 correct?

+16

Dana 20 Rebuild

• CJ
• Mar 16, 2009
• 25
• 2

Images from the Dana 20 Rebuild

Yes, that's correct. I've already ordered a new bottom cover for it. The original one is warped around every bolt hole. No wonder they used so much RTV!

 

[CJ]

Silicone is not just for boobs!

 

[BMK84CJ572]

Silicone is not just for boobs!

Oh, I'm sure I'll go through some silicone too, but more as a belt and suspenders approach for certain areas instead of as my only hope! As my dad likes to say, " in one hand, and wish in the other and see which one fills up first!"

 

[BMK84CJ572]

Update 12/30/24:

I ordered a new countershaft. The only one I could find was on eBay. It had some slight corrosion, but it appeared to just be superficial surface rust. Worst come to worst I'll get a piece of stock and turn it on my father's lathe and cut the groove on the back side with the mill.

The kits from Novak should come in sometime this week, hopefully the countershaft and bottom cover for the Dana 20 come in as well. I got most of the exterior parts cleaned, coated in ospho, 2 coats of primer and 2-3 coats of black paint. Still need to do the top cover for the T-15 and the bottom cover for the Dana 20 when it comes in, but so far so good. I'm looking forward to getting the parts and getting it all put back together and on the Jeep!

 

[KRUPP]

Looking good.
We’re both in the same boat now - I’m waiting on a delivery from Novak as well.
My parts are for a NP435 to mate to my Dana 300 .