I pulled the head on Patterson last night. I don’t see any cracks in the block nor do I see any obvious signs of coolant, though there might be a tiny bit of residue on the tops of pistons 1 and 2. My initial reaction is that coolant is entering the oil elsewhere. The engine does appear to have a recently replaced water pump. Anyway installing that incorrectly would result in mixing coolant and oil??

The first two photos show how the pistons and head gasket looked right after pulling it. 

Then after pulling off the gasket and vacuuming up the dirt:

The head gasket:

The bottom of the head:

I made an puzzling discovery about bell cranks the other day. I ordered a rebuild kit for Rusty’s bell crank. When I began assembling it, I discovered the original and new bolts were different. So, I had to use my old bolt (which fortunately was in good shape). Going back online, all the bell crank rebuild kits show the left hand bolt below (anyone need a new bolt .. I don’t). Do any other jeeps use the shorter bolt in their bell cranks?

Both of the DJ-3As have the same setup. The bolts they use lack an indent (used to secure the bolt to the bell crank mount). They are slightly shorter and 1/16th larger in diameter than the replacement crank. The DJ bolt lacks the hole at the end.

Here it is reassembled. The horizontal bolt clamps the unit together, but does not anchor the bolt.

UPDATE II: Add are some instructions (thanks Terry!) for installing DJ-3A seats:

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ORIGINAL POST UPDATE MAY 2017: I’ve added a couple pics at the end and included a discussion on the extra channel DJ-3As have.

Last fall, when disassembling Rusty, I thought it was odd that the 2/3 1/3 seats had been mounted on wood blocks. I assumed this had been done by the previous owner to raise the seats.

Yesterday, I discovered that Patterson’s passenger seat was loose. When I examined it more carefully, I learned that it was loose because one of the wood blocks under the seat had broken. I can only conclude that all DJ-3A’s with 2/3 1/3 seats were mounted on wood blocks? Or maybe only the early ones?

The photo below shows the passenger seat tilted forward. The front of it is mounted in a way that allows it to pivot forward. The mounts are bolted through a piece of wood, then through a piece of cloth, through the body, and into a welded bolt. The rear of the seats rests on the two mounts at the back of the well. The long piece of wood is a well-seasoned (at least 45 years old) and stained piece of oak that will work perfect for replacement blocks.

Unlike the passenger seat, the rear of the driver’s seat rests on two posts; slide onto the ends of the posts are rubber feet. Those rubber feat sit on blocks of wood also. 

A close up of the rubber foot. The hole is 1 inch in diameter, so I ought to be able to find rubber feet to replace these tired ones.

This shows how great the floor on this DJ is.

Another angle. Blocks 1, 4, 5, and 6 were the same size. Blocks 2 and 3 were larger and screwed down to the body. The rear 2/3’s seat rested atop those blocks.

I’ve drilled cut and drilled the blocks. They are ready for installation. I plan to add a thin piece of rubber under the blocks. Once I remove the rusted end of one bolt that broke, I’ll be able to reinstall the seats.

If you take a look at wood block #1 and block #6 there’s something curious. While the body area under wood block is similar to a CJ-3A, the body area under #6 has an additional channel (btw, we’ve yet to document any under DJ-3A body channels with wood in them).

This is the passenger side with the extra channel and a welded bolt.

No channel on the driver’s side even though there is a bolt welded there. 

Finally, the DJ-3As used wood blocks between the frame and transmission crossmember.

Another item I tackled yesterday was Patterson’s windshield, specifically the twisters and a rear view mirror.

It wasn’t until yesterday that I realized Patterson didn’t have a rear view mirror. Fortunately, I had the mount from Rusty and a nearly correct mirror thanks to Chris McKay. This is before I added the mirror:

And after the mirror. 

Next I addressed a couple of broken twisters. These are one of the unique features of a DJ-3A Convertible. The windshield is nearly like a CJ-3B, accept for the way the convertible top is supposed to attach to the windshield. Instead of a sliding mechanism, it uses those twisters. Two of Patterson’s twisters were broken. I had a few that I removed from Rusty (most of Rusty’s were broken), so I installed two of those onto Patterson. 

The windshield is now complete and ready for a convertible top.