SPECIFICATIONS

VEHICLE
Make: Willys Motors, Inc. Toledo Ohio, USA
Model: Jeep Utility Wagon 2 door, 6-230 4X4*
Year: 1965 (built 1964) Note: apparently, Willys Overland would use the date of sale as the stated year of the vehicle. Thus even though this vehicle was built in '64, it was not sold and "titled" until the next year.
Body Variant: one piece front windshield; extended round tail lights
Colors:

• Body
  • original:#223 Nordic Blue Poly (Metallic)
  • 2006 respray- Sherwin Williams Ultra 7000 metallic blue U7-42181
• Top
  • original:#224 White Cap
  • 2006 respray - Sherwin Williams Classic White B7 - 143 (1972-84 Chevrolet)
• Interior, seats & panels - Blue
• Interior, headlining - Light blue

* Note: In all references: 4X4 or 2X4 = wagon; 4WD or 2WD = pickup truck
Strangely, the back tailgate of wagons has a decal marked "Jeep 4WD"!

CHASSIS
wheel base: 118”
track front: 57”
track rear: 57” (note: Pick-up has 63.5")

Turning radius 25' for 4X4 wagon and 4WD pickup
height: 75” (with fresh springs)
length: 183”
width: 73”
ground clearance: 8” (with fresh springs)
Gross weight (GVW): 6000 lbs
Curb weight: 3311 lbs
Fuel tank capacity: 15 US gallons (56.8 litres) Note that the original fuel tank has been replaced with a new custom unit that uses a vented Chevy fuel level sensor. This unit has provision for a "return" fuel line from the carb. Apparently one of the reasons older engines fail Emissions tests is due to the float being at maximum level all the time. This can translate into an chronically over-rich mixture and thus an excessive unburnt hydrocarbon reading. The "return fuel line decreases this problem.
Cooling system with heater: 13 qts (12.3 litres)

ENGINE
Type: "Tornado" single overhead cam/cross flow head straight six cylinder
Designed by: A.C. "Sammy" Sampietro - Willys chief engineer

See here for development of this engine (380W variant produced 220hp!)

Displacement: 230 cubic inches (3.77 litres)
Bore: 3 11/32” (84.93 mm)
Stroke: 4 3/8” (111.12mm)
Alloy: cast iron head (siamesed intake ports/individual exhaust ports) and cast iron block
# crankshaft bearings: 4
Intake valves: 1.89" Siamesed intake ports
Exhaust valves: 1.61" Individual exhaust ports
Cam lobes shared by intake & exhaust rockers
Cam lift: 0.375"
Cam duration: 250 degrees
Firing order: 1-5-3-6-2-4
Weight: 575 lbs (665 with carb,generator and starter)

Compression Ratio: 8.5:1
Compression Pressure: 145-155 psi
Horse power (brake max): 140@4000rpm
Torque (max @ 1750rpm): 210 ft-lb

Idle: 590 - 600 rpm
Carb: Holley 2 barrel model 2300 Tag: R-2415-A
Gas filter (in-line) NAPA Gold 3087
Fuel pump: Carter MP-3454S

Spark plugs: Bosch W7BC set @ 30 thous
Distributor: Prestolite 1AT 4416 7W
Points: Standard: AL-5486XP set @ 20 thous
Distributor Rotor: Standard AL-151

Ignition advance: 6 degrees BTDC (will accept up to 20 degrees before pinging)

Values for stock Ignition Map.........these values were received from Chrysler Archives

2010 Ignition Upgrade:
Ford EDIS-6 (Electronic Distributorless Ignition System) with MegaJolt Lite Junior controler designed by Brent Picasso of AutoSport Labs.
Ford ECU: part no. 906B-12K072-BA, 0-276-B, 6C05HJC
Ford Coilpack: part no. F5SU-12029-AA 12volts E5167
Spark Plugs: set at 40 thous
Ford CPS (Crank position sensor): part no.
MegaJolt Lite Junior controler V4 with surface mount circuit board

Global values:

• Error in positioning of the homemade 36-1 'Trigger Wheel' that is the reference for the CPS: 2 degrees
• Advance for engine starting (0-500 RPM): 0 degrees BTDC
• Limp home (default) setting: 10 degrees BTDC (should the MegaJolt controler fail or simply be turned off or disconnected, the Ford ECU reverts to a set 10 degrees Before Top dead Centre)

Values for Ignition Map ………

See here to view Ignition upgrade details

Radiator cap: Stant 228 (7 lbs)
Thermostat: 54mm Napa 33008 170-180 degrees F

FLUIDS & FILTERS:
Engine Oil: 15W-40 Note that engines with 'flat tappets' require additives like zinc for surface protection. Shell Rotella or Amsoil 10w-40amo/20w-50avo may decrease wear radically.
Oil filter: Fram PH8A; Kralinator L22
Coolant: Prestone Longlife antigel
Power steering fluid:Castrol GT
Power steering filter:Napa 8953
Gas filter (in-line) NAPA Gold 3087

CLUTCH
Original - Auburn/Borg&Beck 11”
Now - Fenco CP3036 11" disc

TRANSMISSION
Make: Warner
Model: T90-J (3 speed)
low: 2.798:1 2nd: 1.551:1 high: 1.000:1 R: 3.798:1

TRANSFER CASE
Make: Spicer
Model: 18 (2 speed) May be known as a D-18
low: 2.46:1 high: 1:1

PTO: Koenigs model 41 unit attached to Transfer Case with mechanical Koenig's winch on front bumper (see WINCH below)

FRONT AXLE
Make: Dana
Model: Spicer 25 (as found in all 4X4 Pickups & Station Wagons)
Ratio: axle has optional 4.27:1 ratio (originally was from Montana) Most common ratio was 4.88:1 with the second option being 5.38:1

Locking Hubs: Cutlas PowerLock

REAR AXLE
Make: Dana
Model: Spicer 44 (as found in all 4X4 Station Wagons - 4WD Pickups have 53; 2WD PUs & 2X4 Wagons & Jeepsters have type 27)
Ratio: axle has optional 4.27:1

STEERING
original Make: Ross
original Model: TL-12 (4 1/4 turns lock to lock)

2006 steering upgrade: Saginaw "Recirculating Ball" type power steering box.
make of steering box: 1980 Jeep Cherokee(GM)
model of steering box: Saginaw metric 3 bolt (4+ turns lock to lock)
Steering column: 1985 Jeep Cherokee tilt
Steering linkage: 1985 Jeep Cherokee collapsible with vibration damper & 16” Borgeson intermediate splined shaft, U-joints and support bearing

NAPA power steering fluid filter 8953

WHEELS
5.0 x 16”, 5 on 5 1/2" (139.7mm) bolt pattern

TIRES
Make: Armstrong
Model: Desert Dog
Size: LT235/85 - 16”
Wheel diameter: 30.25" (measured) - this is identical to the stock 7.00 X 16 original tires

BRAKES
Make: Wagner?
Model: 11” drum
swept area: 176.2”

2007 front brake upgrade:
Chevy '71-'78 1/2 ton or light 3/4 ton Dana 44 front caliper brackets and calipers

Pads: NAPA TruStop TS728AM
Rotors: '77/'78 CJ5 vented rotors (1 1/8" thick) Raybestos 3550R
Brake hoses: Chevy 1/2 ton OEM Napa 36759 (right), 36760 (left)

Combination Valve: '97 Jeep TJ .....Note: this valve is actually three valves in one: a Metering Valve which engages the rear brakes before the fronts; Proportioning Valve which allows only a certain percentage - perhaps 70% - of the hydraulic braking pressure to go to the rear wheels; a Pressure Differential Switch which detects if one of the the two brake circuits has lost pressure - a dashboard light is illuminated.

2007 dual master cylinder upgrade:
Raybestos MC36456

• originally designed for AMC Hornet SST & Javelin vehicles
• master cylinder bore: 1-1/16"
• ports for brake lines are both 1/2" X 20tpi

Note: the 1971-78 Chevy pickup calipers had a 1-1/8" piston in their GM factory master cylinder - this 1/16" difference in piston diameter will no doubt cause a longer brake pedal travel than expected.

front and rear brake lines separated into 2 circuits

SPRINGS
Front: 10 leaves with front shackles
Rear: 8 leaves with rear shackles

Carl Walck's USA made replacements (2011) have an extra short leaf at the bottom of each stack.

SHOCK ABSORBERS

Front shocks should be: 11 1/2" - 17 7/8" Monroe 32207 gas shocks almost give these lengths.
Rear shock lengths should be: 14 1/4" contracted & 23 1/8" extended. Monroe 31094 gas shocks give almost these values.

WINCH
Make: Koenig's Winch
Model: 100 King winch "Lower Mount".....Note: there are "Side Mount" and "Lower Mount" versions of this winch. The Lower Mount uses 2 bolts through the bottom of each 'A frame' shaped bracket assembly.

Gear oil for Koenig's King winch (manufacturer recommended): EP150W

BODY
Upholstery: front seats reupholstered with OEM materials from SMS Auto Fabrics in Portland Oregon
Seat Belts: 1990 Dodge caravan 3 point (shoulder) retractable belts & 2 sets of middle seat lap non-retractable belts
Sunroof: not installed
Gauges: Original fuel and temperature gauges are supplimented with ammeter, oil pressure (as well as a modern radio). In future, all additional gauges could be hidden behind the metal blank on the dashboard in front of the steering wheel. The metal blank would hinge downward so that the gauges/radio can be viewed and accessed. The idea for the concealed gauges came from the now defunct “Wicked Willys” website:(http://www.slick-willys.com/wagon.htm)