61 CJ5 Resto Restart Info

[bmorgil]

If you can find a copy of your original 1961 Jeep Service manual, you might find them there. There are some torque specs in the back pages (Section U p275) of the -R6 reprinted Universal Manual. You have to be careful with the Universal Service Manual however. Sometimes the spec varies by year and the manual seems to have most of the specs from the 1965 models, the year for the CJ's when the manual (Form SM-1002-R6) was last reprinted by Jeep.

When you cant find the spec, you will have to use the SAE Bolt torque guide. I have bumped into that a few times.

[gmwillys]

Here is a quick reference for fastener torque specs.

https://www.engineersedge.com/torque..._sae_ftlbs.htm

[bmorgil]

The SM-1002-XX manual was reproduced in a running format. Each edition was intended to cover prior model years. Sometimes the prior specs and process were left out. The -R 1 through 6 indicate the reprint edition with -R6 being the last one. The -R6 is the one I received from KW. Here is a link to some of the older editions.

This is a link to some of the original reprints. You can only look at the covers, I think this Link is to Walks old site. It is no longer functioning. If you want to try to get these publications, Mike at KW should know how to try to find them.

https://www.willysjeepparts.com/CJ_DJ_Service_Manuals.htm

Here is another source for old manuals on CD:

https://www.bishauto.com/shop?ti=jeep-1ef9&yrF=1950

[test1328]

Thanks for the references, Bmorgil! I'll have to look into that. I've got the torque references for different bolt sizes and grades, but so many things on the Jeep don't use standard bolts/nuts and I hate to just rely on what I find on the internet, although most of the time, the internet stuff is accurate. I'll try to find one of the actual service manuals somewhere.

[test1328]

Been quite a while since I last posted. Can't say there has been a ton of progress made due to my boys' Spring and Summer baseball seasons and then taking them out to CA to go to school. Also had a ton of house projects this summer. Now I need to prepare for hunting season, so there seems like there is never enough time to work on the Jeep. However, I did accomplish my main goal for this summer and that was to get the hardtop and body off of the frame so I can more easily work on the heap. I needed to get that done before my boys left since I needed their muscle to carry them across my yard to store them outside of the shop. Here are a few pictures. I made the boys pose for posterity!

hard top & body.jpghard top & body w boys.jpgFrame.jpgFrame2.jpgFrame3.jpg

You can see that I've mostly been working on the front end. Now I can start on the PTO, Transfer Case, and Transmission. Getting the body off the frame was a chore. Many rusted bolts that had to either be cut off or ground off since they wouldn't turn. Fortunately, the hard top came off relatively easy. Pretty amazing since it has never been off since it was put on in '61. Those steel tops are not light, that is for sure.

One question that I have for you guys that came to mind after the body came off is in regards to the wiring harness. The wiring on this Jeep is actually in pretty decent shape for being so old. However, it is obviously quite old. I was wondering what you thought about the wiring harness from KW and if you thought that would be the better thing to do as opposed to continuing to use the original wiring? Anybody with experience using their new harness and any problems or issues encountered?

Best regards,
Paul

[bmorgil]

That has been a popular conversation. Here is one thread we had on it. There are a few more if you search for "Wiring Harness" but I think this thread had a few sources and ideas. I know TJones likes the Painless Wiring Harness.

https://willysjeepforum.kaiserwillys...Wiring-harness

That baby is coming along nicely! That is a clean CJ you have there. That will turn out very nice! The boy's will love it.

[gmwillys]

There never seems to be enough time in the day.

As far as the wiring harness goes, The Painless wiring harness that TJ used is a great option especially if you are going to do a custom build. It works extremely well as an all new, modern electrical system. Modern fuse panel with blade fuses make for a great platform to any future additions. With that being said, the harness that KW offers is great for an original style restoration. It all boils down to what you'd like to see when you open the hood. Both will get the job done and will look good when ran. One will look original, where the other will function and still look clean. I like the original look, but also do not mind the functionality of the new harness.

[LarrBeard]

"Anybody with experience using their new harness and any problems or issues encountered?"

I bought a KWAS harness for the '48 truck and I have not regretted it in the least. The new harness laid right in, the ends and terminations came out in the right place, the wires were period correct and the right colors. (There was one intermittent crimped contact - on the horn button - that drove me nuts for about three years).

If you are going to go to the trouble to clean up the chassis and body, a new harness would look nice in there. The other consideration is that although the old harness looks pretty good, it only takes a couple of intermittent connections, broken wires or bad contacts to drive you nuts trying to find them.

Yeah, it's more money, but it may be money well invested.

[test1328]

Thanks, guys, for all the responses on the wiring harness. I suppose you have confirmed for me that my concern or worry is not unfounded about having problems in the future with the wiring if I just left the original wiring in place. I'd hate to have a pristine looking vehicle with recurring wiring issues that I have to track down and fix. As I've been working on this, I've also had to confront the question of do I leave it stock or do I try to improve things like brakes, alternator, headlights, etc. and have come to the conclusion that I'd rather keep everything stock in appearance and function. Therefore, it sounds like a KW wiring harness purchase is in my future. I'm really not looking forward to replacing all the wiring, especially under the dash, but I guess it's a necessary evil. Thanks again for your input.

[LarrBeard]

"I'm really not looking forward to replacing all the wiring, especially under the dash,"

If you go with a KW harness (or similar one) the good news is that everything is going to be the right length and it will lay into place without an undue amount of fussing and stretching.