1981 Jeep CJ5
 

I need another project about like I need to be ran over by my first one. I've always wanted another CJ since having my CJ7 many years ago. This CJ5 popped up at too good a price to turn down.
If I don't get tied up I will go get it this weekend. About 1.5 hours north of me.

Re: 1981 Jeep CJ5
 

Looks real nice..!!..
I always wanted a cj7..

Re: 1981 Jeep CJ5
 

Nice looking CJ5. I have an '86 CJ7 and the best thing I did was to tear out all of the emissions. With the stock emissions, carb, and ignition you couldn't let it run in the garage for 20 seconds or your eyes would be watering from the exhaust fumes. I did what I remember being called a "nutter" mod with the emissions/ignition, and I also swapped to a different carb and now that 4.2 inline with 150K+ miles runs strong and clean.

Interested to see more of it once you have it.

Re: 1981 Jeep CJ5
 

Looks like the plan is to go pick it up this Sunday. Will shake down the good, the bad, and the ugly at that point. I know someone has installed a push button starter switch on it so I anticipate a lot of messed up wiring and such. Jeeps of this area are still as simple as our old trucks so I'll sort it out and fix it right.

Re: 1981 Jeep CJ5
 

It is in its new home. Figuring out what I got for my money right now.

Re: 1981 Jeep CJ5
 

Getting ready to get serious on transfer case and transmission removal.

Re: 1981 Jeep CJ5
 

What engine and transmission does it have? Why are you dropping the transmission and T-case?

Re: 1981 Jeep CJ5
 

Has the 258 inline 6 in it. Needs a new flywheel and starter so I figure I’ll put a clutch and throw out bearing in it while I have it all apart. Flywheel is seriously messed up teeth wise and ruined the starter.
This should get it running and driving and then I’m going to start a list on what else. May end up getting a new wiring harness as the wiring has been jacked with a good bit.
Engine numbers seem to point it to being 1983 and it has a T150 3 speed transmission with a Dana 20 transfer case. Those cannot be newer than 1979. While not overly crazy on the 3 speed the Dana 20 is a good case.

Re: 1981 Jeep CJ5
 

Following along as my CJ needs a clutch as it sometimes chatters when it's warm. Mine is the 4.2 with the 5 speed manual which I feel is the least desirable of the manual transmissions with the 4 speed being the best. I'd much rather have your 3 speed than this week 5 speed that likes to whine in 5th.

Interested to see how it goes for you. It seems there are a lot of clutch kits out there.

Re: 1981 Jeep CJ5
 

The good thing is it appears the clutch and flywheel pretty much remained the same for years on the 258. I have read, watched a few videos, and asked one of my buddies in Kansas City who’s a jeep nut.
I will take some photos as I pull it all out and give an update. Was going to do it today but have to head to a paper mill to fix a flow instrument so they can get a boiler on line.

Re: 1981 Jeep CJ5
 

Well, this is the pile after I got down to the crank. Not overly tough, just takes time. I have determined it needs motor mounts, too. Has the wrong skid plate for this transmission as well. I'll fix it all up right when it goes back together.

Re: 1981 Jeep CJ5
 

New flywheel, clutch, pressure plate, and pilot bearing installed this weekend. As I suspected, the pilot bearing was incorrect and oversized for three speed T150 transmission. The input shaft was probably wiggling around with the old one. Working on cleaning up the bell housing and waiting on gaskets to seal up the transmission after inspection. Had to make some 1/4” diameter shifter pivot pins as one was missing and the other pretty worn.
Blasted and painted the shield and inspection covers as well. Waiting on the correct skid plate and transmission mount to arrive as well. Started scrubbing the drive shafts for paint and installing new u joints.

Re: 1981 Jeep CJ5
 

Wow, nice work!

Re: 1981 Jeep CJ5
 

Received the correct skid plate/transmission mount. Will clean up and paint this weekend. Got new motor mounts, transmission mount, and transmission gaskets on order. While waiting I decided to clean up the drive shafts, paint, and install new u joints. Cleaned up the bell housing and installed the new throw out bearing. Waiting on the new clutch fork boot to arrive and then it's going in.
Once I get the new motor mounts/transmission mounts installed I will install the new clutch bell crank and pieces.

Re: 1981 Jeep CJ5
 

Got this all put back in over the weekend. Good news, the backup light switch works. Bad news, found a broken motor mount bracket on the passenger side and the correct transmission mount will not clear the cobbled up exhaust system. So, my next step will be to cut out all the junk exhaust to get the transmission and transfer case mounted correctly. Then pull the motor mount bracket for repair.

"Wow, it's in better shape than I thought" was never said by a used jeep owner.

Re: 1981 Jeep CJ5
 

Reminds me of my ole CJ5. Cool Jeep.

This was mine. It had the 258 inline in it. It took that hill across from me with no sweat. Never failed me.

Somebody wanted it more than me and offered me a lot of money so I sold it. Probably shouldn't have.


http://67-72chevytrucks.com/gallery/...ium/Jeep80.jpg

Re: 1981 Jeep CJ5
 

Paul,
I hope someone with more money than sense runs across me and wants this CJ when I’m done. I’ll drive it until then.
Got the transmission and all back in. Let the wife crown it off with the new shift knob.

Re: 1981 Jeep CJ5
 

If you find "more money than sense" guy...send him my way..!!!!.. haha

Re: 1981 Jeep CJ5
 

Right now I think I am that guy for getting another project started. And it's not that I have a lot of money, I just have less sense.

My biggest issue is I can put up with rust and less than perfect body but when it comes to the functional stuff I have to fix it correct or better than factory. This jeep just needs dozens of little things corrected. Then I'll tackle the looks department.

Re: 1981 Jeep CJ5
 

Been a slow go with all my other side track projects but I have the transfer case ready to go back in. Rebuilt the single stick linkage and got the majority of the slack out of it. Hope to get this and the drive shafts back in this weekend.

Re: 1981 Jeep CJ5
 

Looking good!
So how is the body on the jeep?

Re: 1981 Jeep CJ5
 

Body is ok, no real damage other than passenger side front fender needs a little work. Rust wise I guess it’s average. Both front floor pans will need replacing as well as one spot on the drivers side that is rusted through. It has been repainted once and done very poorly.

My plan is to build an off road jeep, not a street jeep. Therefore, my skill level of bodywork and paint is probably good enough. Definitely better than whomever was working on it before.

Re: 1981 Jeep CJ5
 

Driveline is all back in and full of gear oil. Ignition switch does not work in the START position so I have a push button wired in under the hood. Pulled the plugs and turned the engine over with the starter a few times to make sure all was well. Plugs show the engine to be running rich so I’ll clean them up and put them back in.
The under hood wiring is a mess so I am going to temp in power to the coil and ignition box tomorrow. Have disconnected the fuel tank from the pump so my plan is to bottle feed it and get it running. After that I’ll run through the entire fuel system.
So much to work out but one thing at a time.

Re: 1981 Jeep CJ5
 

Got us a runner it looks like. Installed a new fuel pump and plumbed up a 2 gallon jug to see if this thing would fire. After fighting the new fuel pump to get it primed I hot wired the ignition and she fired up without much trouble. Was able to run the engine long enough to get the thermostat to open and circulate some liquid. Now moving on to pulling the fuel tank to clean it up and the supply and return lines.
Working on pulling the dash as well. Need to work on the clutch/brake pedals. The jeep was originally a hydraulic clutch setup and someone in the past converted it to linkage and done it very poorly. While not as good as hydraulic, I am totally rebuilding the linkage clutch system, which includes a different clutch pedal. Already installed new bell crank and associated pieces.
Got an oil leak in my newly installed transfer case. Thought I got all the inspection cover bolts sealed up but I hope it's just one of those.

Re: 1981 Jeep CJ5
 

After getting the running gear back installed and then getting the engine running I started making a list of things I wanted to do mechanical and body wise. Got the fuel tank out, cleaned, new fuel sending unit installed, skid plate painted, and ready to go back in. Decided to wait to finish the exhaust.

Last weekend I went through my list and made an executive decision. The only way to get this rig the way I want it was to get the body off. So here we go, hope to have it all stripped down with the body off by the end of February.

Re: 1981 Jeep CJ5
 

While it is not exactly falling apart on its own, some progress is being made on the disassembly. Current state and thoughts on where I heading, color wise.

Re: 1981 Jeep CJ5
 

I like the color you're suggesting. Thoughts on adding graphics? My '86 is a Renegade so I added them after I redid it as I've always liked the over the top CJ graphics.

Re: 1981 Jeep CJ5
 

Have not considered graphics but might start looking now that you mention it. My 79 CJ7 was a Renegade and I always liked the graphics.

See? More scope creep. It's what I do.

Re: 1981 Jeep CJ5
 

Nice! I'm a Jeeper, too. I've had my '98 for 21 years now and it's still going strong. :)

Re: 1981 Jeep CJ5
 

KS,
Super. This project was purchased for my wife and daughter. I think they picture themselves tooling around town and back roads on good weather days. I'm ok with that as long as I get to take it when I go fishing.

Re: 1981 Jeep CJ5
 

My be time for a LS swap?
My LS swapped 98 Wrangler has been great.
My Wrangler is truly a mall crawler. Summer time cruiser. Snow plow in the winter.

Re: 1981 Jeep CJ5
 

LS,
Nice! That V8 looks like it was supposed to be there all along. Great work.

Don't get me to thinking any more scope creep thoughts. This was going to be a few months of fixing the broken stuff and then driving it. Well, here we are now pulling the body and diving in.

Re: 1981 Jeep CJ5
 

Scope creep is where I went with my Wrangler. When I bought it it was a 4 cylinder 5 speed combo. Crazy slow.
So I started picking at it and pretty soon the body was off the frame. Sand blasted the frame, powder coat it, 8.8 Explorer rear axle, 241R TC, rebuilt LS6/4L60E and then a total repaint.
I've got 15 years on the swap. It's been great. Had it on the Power Tour a couple of times. Only goes to the end of my driveway in the winter. It's a bit scary in 2 wheel drive on snow. It does the best donuts on snow vehicle that I've ever had!
So I encourage scope creep. Never know where it will lead you.

Re: 1981 Jeep CJ5
 

Steering column time. Well, it really should not be as I will not need it for a good bit but I picked up a decent, used column and am now in the process of taking two columns and making one good one.

Re: 1981 Jeep CJ5
 

Cool to see you tackling everything that needs attention.

Re: 1980 Jeep CJ5
 

Small progress over the weekend. Steering column almost back together and once the body mount bolts come out the body is ready to pull from the frame.

I think I already know the answer here, but my guess is I should replace the rusty floor pans before removing the body from the frame so everything stays in place.

Re: 1981 Jeep CJ5
 

I'd say it's sitting in the best possible position for floor pan replacement the way it sits in your last pic there, so that's what I'd do next. Worst part of any build (rust fixing) so best to just get it done.

Re: 1981 Jeep CJ5
 

Willowrun,
Thank you, those were my thoughts as well. It's the part I am dreading most so I might as well jump in and get it done. Think I will roll it out of the shop and pressure wash the snot out of everything and then start the process.

Re: 1981 Jeep CJ5
 

Here we go! New floor pans are supposed to be here tomorrow so I started on a bit of investigative surgery. I will most likely have to go further on that hole up to the left, but I will start there and sneak up on the good metal. Rust follows the floor pan up to firewall quite expectedly.

You can also see the terrible second paint job on this thing that must have been done with a mop and zero prep work. It will all get blasted to bare metal and start from a clean base soon.

Re: 1981 Jeep CJ5
 

Well, the real fun is about to begin. A few exploratory cuts and the big brown truck delivered the floor panels last Friday. Was concerned with the holes in the box from obvious rough treatment, but the pieces were in good shape.