1. Preparation & Safety:
* Disconnect the Battery: This is crucial to prevent accidental shorts.
* Gather Tools: You'll need various tools including:
* Socket set (metric and standard)
* Wrenches (metric and standard, including open-end, box-end, and possibly a torque wrench)
* Screwdrivers (Phillips and flathead)
* Hammer
* Pry bar (plastic or wood is best to avoid scratching the frame)
* Jack and jack stands (multiple sets are recommended for safety)
* Penetrating oil (like PB Blaster)
* Safety glasses
* Gloves
* A helper (highly recommended!)
* Plan Your Workspace: Choose a level, stable surface with ample room to maneuver. You'll need space to lay the body down safely once removed.
* Photography: Take lots of pictures before you start disconnecting anything. This will be invaluable during reassembly (if you ever plan on it) or even just for reference. Note wire routing, hose connections, etc.
2. Body Removal Process:
* Exhaust System: Disconnect the exhaust system from the body and the frame. This often involves loosening clamps and bolts.
* Wiring Harness: Carefully trace and disconnect all wiring harnesses from the body. Label wires if possible to simplify reassembly or future troubleshooting. Use electrical tape to mark and protect disconnected wires.
* Fuel Lines: Disconnect the fuel lines. Be sure to relieve fuel pressure before doing so.
* Brake Lines: Disconnect the brake lines. You will need to plug the lines to prevent fluid loss.
* Body Mounts: The CJ5 uses body mounts (rubber bushings) attaching the body to the frame. These are usually bolted. Apply penetrating oil to the bolts well in advance to help them loosen. You'll need to remove all bolts securing the body to the frame. Work your way around the Jeep systematically, removing bolts one at a time.
* Steering Linkage: Disconnect the steering linkage from the steering box.
* Shift Linkage: Disconnect the shift linkage from the transmission.
* Windshield: It might be advisable to remove the windshield to reduce weight and improve access.
* Doors, Hood, Fender: It's generally easier to remove these before lifting the body to avoid damage. Remember to disconnect all wiring and linkages.
* Lifting the Body: Use the jack and jack stands to carefully lift the body from the frame. Start on one side, then the other, working slowly and steadily. Have a helper guide the body as it lifts and use wooden blocks or similar for protection to avoid damage. Once fully lifted, carefully lower it onto sturdy supports.
3. Post Removal:
* Clean the Frame: Thoroughly clean the frame to prepare it for the new body kit.
* Inspect the Frame: Carefully inspect the frame for any rust or damage before installing the new body.
Important Considerations:
* Rust: 1983 CJ5s are prone to rust. Expect some challenges removing rusted bolts. Use penetrating oil generously and be prepared to use heat (carefully!) if necessary. Broken bolts may require drilling and extraction.
* Body Damage: Be gentle to prevent further damage to the existing body, especially if you plan to reuse parts or sell it.
* Professional Help: If you're uncomfortable with any of these steps, consider seeking professional help from a mechanic or Jeep specialist. This is a complex project.
Remember safety first! This is a physically demanding project. Take breaks when needed and don't hesitate to ask for help. A well-documented process with pictures and notes will make this task much less daunting.
