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DJ3A DISPATCHER COLUMN SHIFT REPAIR ; Also early CJ2A
Topic Started: Sep 1 2014, 10:03 PM (4,192 Views)
PapaC
Papac
[ *   *   *   *   *  ]
Both very early CJ2A's and most of the DJ3A,s with the exception of a very few 'Delivery DJ's' were equipped with with a column shift transmission remote control.

Considering most of the moving parts in these shift mechanism's are direct metal to metal contact I can't imagine there are very many hard run survivors that are in even close to the original specs due to wear.



Here's a exploded view from the willys manual of the column shift mechanism.

Posted Image

As you will see this list and view has more than a few problems for the restorer.

Having already taken mine apart here's a few of the problems I'v encountered and will sorting out as this restoration begins to take shape.



#1.

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The shift lever itself is heavily pitted and the ball end badly worn. No clear pictures anywhere for comparison that I can find so I'll use what's there to try to obtain the clues to reconstruct.

#2.

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The end of the steering tube seems to be a bit out of round.


#3.

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Pin holes wallered out and edge broken.
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
#4 and #5

Posted Image

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Both of my first reverse and second third levers look like this.


My anti rattle springs were completely missing so once again it's down to reinventing the wheel here!!

Another problem which will require close attention to sort out is the counter sink on one side of both levers.
That one I havent solved yet!!
Wear, factory, ?

EDIT. Factory counter sinks

#6.

Posted Image

The parts list image doesn't exactly tell us this this should be a 'semi' square peg in a round hole!!

Mine is neither round on one end .......nor square on the other end where it's supposed to be!!!!

#7. No information given on the cross shift bias spring, ie. size, length, and rate of compression.

My springs in pieces but hopefully enough left to figure this out when I get a chance to examine more closely.
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
And last but not least, not by a long shot.

There's a very interesting lever fulcrum pin, #5 on the parts list with a flair on one side and a screw on the other side (no picture but I did manage to track down what it's supposed to look like) that will be needed to replace the rusty bolt and nut that was holding mine together!

In the coming days I will attempt to bring this worn out and small parts missing shifter remotes back up to spec and something to be proud of. In so doing, I'll attempt to bring to light and solve all of the missing pieces of the puzzle that are contained in that parts breakdown.

Charles
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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SteveK
Member
[ *   *   *   *   *  ]
Charles, mine is still apart so let me know what you need a pic of. I'll look, but I don't remember the wear and tear on mine (with 87K miles) as yours has, as I've already painted mine. My main 'wear issues' were on the clutch pivot lever holes and links. I'll look for those bevels and let you know what I see.
SteveK
62 Dispatcher
South Florida
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SteveK
Member
[ *   *   *   *   *  ]
Quote:
 
The parts list image doesn't exactly tell us this this should be a 'semi' square peg in a round hole!!

Mine is neither round on one end .......nor square on the other end where it's supposed to be!!!!


Where is that located. It's been a couple of years since I've seen mine, but I don't remember anything like that. Maybe I'll see it when I check for bevels.
SteveK
62 Dispatcher
South Florida
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PapaC
Papac
[ *   *   *   *   *  ]
SteveK,Sep 2 2014
05:00 AM
Quote:
 
The parts list image doesn't exactly tell us this this should be a 'semi' square peg in a round hole!!

Mine is neither round on one end .......nor square on the other end where it's supposed to be!!!!


Where is that located. It's been a couple of years since I've seen mine, butl I don't remember anything like that. Maybe I'll see it when I check for bevels.



Thankfully that 'square ended round pin in the shift clutch assembly along with quite a few other important details has already been documented over on the CJ2A forum.


http://www.cj-2a.com/oldsite/shifter/clutch/

http://www.cj-2a.com/oldsite/shifter/asm/index.html

Although there is EXCELLENT information there not shown in their rebuild is the length of the cross shift bias spring, any details of the anti rattle springs, a clear picture or understanding of the bevels mentioned, nor a good shot of the ball at the end of the shift lever itself.

Also mine had pretty good remnants of a felt pad used as a type of grease seal for the shift clutch mechanism that appears not to be show on theirs.

Any pictures or other information concerning these details, as would a source for a correct lever fulcrum pin would be surely appreciated!!
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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SteveK
Member
[ *   *   *   *   *  ]
OK, so the clutch pin is inside the assembly that I did not take apart. No wonder I didn't remember seeing it. That means my statement via e-mail for the 'end of the shaft' is wrong. I now see your pic is the 'top of the shaft'. I think that is just 'damaged'.

That is some kinda damage on that pin and handle lever. What kind of shifting were they doing? Steering shaft is pretty beat up too. I'll bet that steering wheel was a bear to get off considering all the rest of the conditions. I know mine was.

At least now I know what to look for in that pin for the handle. A screw into the pin, and I remember seeing the bias spring, so I can get that measurement for you. I guess you see now that there is no ball on the end of the shifter handle rod, just a tapered point as in the pic I e-mailed you.

SteveK
62 Dispatcher
South Florida
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
Do a search on the 2a page for jpet's posts on column shifter repair...he made several new shift levers and there should be dimensions..Also if you have any questions about how it is supposed to be, try pm'ing lowenuf over there,. He has restored several cs columns..
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
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PapaC
Papac
[ *   *   *   *   *  ]
Wow. Having help with research is AWSOME and thanks guys!!!

Steve's been a busy camper. Quite a few emails today along with pictures and measurements so that's where I'll start.

Here's a good shot of the bevel in the shift arms and below the pic a quote of the measurements!!


Posted Image


Quote:
 
Steve...The bevels are only on the outter sides of the levers, top and bottom.  The hole is 5/16" -1/16" thick to up to a 1/2" bevel.








Bill, I found the thread where jpet made a batch of the new shift arms. Contained in that thread was a McMaster Carr part number for a similar barrel bolt that can be made work.

http://www.mcmaster.com/#98975a388/=tjzd6g


______________________________

Heres a shot of Steve's shift rod end. As he pointed out there is Not a ball on the end but comes down more to a smooth point

Posted Image
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
Here's mine after some welding and hand filing. My 56 appears more like the ones jpet was making for the early cj's and as referenced by Bill.

Before:
Posted Image

Now:

Posted Image

Posted Image

Note I'll still do a bit of repair on the shoulder around the hole and still need to remove the remnants of the pin that is 'stuck in the middle ' :)
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
More specs on the springs in the dj3a early cj2a column shift remote





From the cj2a forum




http://www.thecj2apage.com/forums/coulmn-s...8473.html#28473





URL=http://s924.photobucket.com/user/ctate1957/media/transmission%20remote%20contro%20willys/image_zpsb492bbf5.jpg.html]

Posted Image[/URL]


Shift lever anti rattle spring (from the cj2a forum)

http://www.cj-2a.com/oldsite/shifter/rattle/

Posted Image

http://www.thecj2apage.com/forums/uploads/...ttle_spring.pdf

Posted Image


Follow the links to the cj2a forum for more detailed information

Charles Tate
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
I remember the shift arm end ( to the right in your picture) being a sharper point, almost like a center punch....As usual this is from memory and I don't have any of it here to compare to.
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
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PapaC
Papac
[ *   *   *   *   *  ]
F Bill,Sep 3 2014
03:17 PM
I remember the shift arm end ( to the right in your picture) being a sharper point, almost like a center punch....As usual this is from memory and I don't have any of it here to compare to.

You're probably right and I kind of did that on purpose.

What I was preliminarily trying to do was leave it a tad larger than needed so that when I repaired the shoulders and test fit it I could also lap it to fit the size of my 'probable' worn oversize hole it fits into and mates with.

Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
And then I welded up the wallowed out holes, dressed them down and re-drilled them to match my new shift lever pin. One big hole for the body of the barrel and a small hole for the home made screw on the other end. (Both ends started their lives out as bolts.)



Posted Image


Posted Image

Posted Image :)
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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ba25
Member Avatar
Member
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cross shift bias springs #4 on chart

Posted Image
Posted Image
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BA Agan

46 Bantam T3-C 2953
46 Bantam T3-C 19638 "Big Red"
49 CJ-2A 222564
51 M38 MC 28115
52 M100 285896
62 CJ5 57548-148683
64 DJ3A 8204-24210
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