1939 WILLYS
Model Designations:
Willys, Model 48, 4 Cylinder
Overland, Model 77, 4 Cylinder
Willys, Model 48, 4 Cylinder Body Styles
Coupe, Base Price: $495
2 Door Sedan, Base Price: $535
4 Door Sedan, Base Price: $555
Speedway Coupe, Base Price: $596
Speedway 2 Door Sedan: $616
Speedway Sedan, Base Price: $631
Special Speedway Coupe, Base Price: $610
Special Speedway 2 Door Sedan, Base Price: $631
Special Speedway Sedan, Base Price: $646
DeLuxe Coupe, Base Price: $646
DeLuxe 2 Door Sedan: Base Price: $667
DeLuxe 4 Door Sedan: Base Price: $689
Overland, Model 77, 4 Cylinder
No Body Data Available
General Specifications, Model 48
Wheelbase: 100 Inches
Engine Type: Inline 4, L-Head
Bore & Stroke: 3-1/8" X 4-3/8"
Engine Displacement: 134.2 Cu. In.
Compresssion Ratio: 5.70:1
Taxable Horsepower: 15.63
Horsepower: 48 @ 3,200 RPM
Torque: Not Available
Rear Axle Ratio: Not Available
Carburetor: Not Available .
Tire Size: 5.50 x 16 inches; Inflation Pressure, Front 28, Rear, 30
General Specifications, Model 77
Wheelbase: 100 Inches
Engine Type: Inline 4, L-Head
Bore & Stroke: 3-1/8" X 4-3/8"
Engine Displacement: 134.2 Cu. In.
Compresssion Ratio: 6.35:1
Taxable Horsepower: 15.63
Horsepower: 61 @ 3,400 RPM
Torque: Not Available
Rear Axle Ratio: Not Available
Carburetor: Not Available .
Tire Size: 5.00 x 16 inches; Inflation Pressure, Front 30, Rear, 30
Tune Up Specifications, Model 48
Spark Plug: Gap .025"
Spark Plug Type: Champion J-8 (2 Rib), J-11, or Equivalent
Point Gap: .020"
Distributor Cam Angle: 41 degrees
Ignition Timing: "IGN" Mark on Flywheel
Firing Order: 1342
Tappet Clearance, Hot: Intake .004", Exhaust .006"
Cylinder Head Torque: 60-65 Ft Lbs
Tune Up Specifications, Model 77
Spark Plug: Gap .025"
Spark Plug Type:
Point Gap: .020"
Distributor Cam Angle: 41 degrees
Ignition Timing: Early Models: "IGN" Mark on Flywheel; Late Models, 5 Degree Mark on Flywheel
Firing Order: 1342
Tappet Clearance, Hot: Intake .014", Exhaust .014"
Cylinder Head Torque: 60-65 Ft Lbs
Carburetor Specifications:
Valve Specifications, Model 48
Tappet Clearance, Running Hot: Intake .004"; Exhaust .006"
Clearance for Timing: Intake: .010"; Exhaust: .010"
Valve Timing: Intake Opens At Top Dead Center
Exhaust Closes 5 degrees After Top Dead Center
Valve Seat Angle: Intake 45 degrees; Exhaust 45 degrees,
Valve Spring Pressure: 46 Lbs @ 2-1/4 inches (New Springs)
Valve Stem Clearance: Intake .002"-.004"
Exhaust .003"-.005"
Valve Specifications, Model 77
Tappet Clearance, Running Hot: Intake .014"; Exhaust .014"
Clearance for Timing: Intake: .020"; Exhaust: .020"
Valve Timing: Intake Opens 9 Degrees Before Top Dead Center
Exhaust Closes 12 degrees After Top Dead Center
Valve Seat Angle: Intake 45 degrees; Exhaust 45 degrees,
Valve Spring Pressure: 53 Lbs @ 2-7/64 inches (New Springs)
Valve Stem Clearance: Intake .0015"-.003"
Exhaust .002"-.004"
Piston & Ring Data
Piston Removal: From Above
Piston Clearance (Minimum):
Top Land Inch .018"
Top of Skirt, Inch: .002"
Fitting Pistons with Spring Scale:
Shim Thickness: .0025 using a 3/4" wide feeler gauge
Pounds Pull on Scale: 5 to 10
Width of Ring End Gap (Minimum):
Compression Ring: .008"
Oil Ring: .008"
Clearance Between Ring & Grooves:
Compression Ring: .0005"-.001"
Oil Control Ring: .001"-.0015"
Engine Bearing Data
Camshaft End Play: Automatically controlled by spring & plunger at front
Camshaft Bearing Clearance: .002"-.0035"
Rod Journal Diameter: 1.9375"-1.9385"
Rod Bearing Clearance: .001"-.0025"
Rod End Play: .005"-.009" inches
Rod Bolt Tension: 50-55 Lbs. Ft.
Main Bearing Journal Diameter: 2.3335"-2.3340"
Main Bearing Clearance: .001" -.0025"
Crankshaft End Play: .004"-.008"
Main Bolt Tension: 60-70 Lbs. Ft.
Capacities, Model 48
Cooling System: 11 Quarts
Fuel Tank: 8 Gallons;
Engine Oil Refill: 4 Quarts;
Grade of Oil: Above +32F 20;
Above +10F 20W;
Above -10F 10W
Transmission: 1-1/4 Pint
Grade of Oil: Summer 90, Winter 90
Rear Axle: 1-1/4 Pints
Grade of Oil: Summer 90, Winter 90
Capacities, Model 77
Cooling System: 11-3/4 Quarts
Fuel Tank: 8 Gallons;
Engine Oil Refill: 4 Quarts;
Grade of Oil: Above +32F 20;
Above +10F 20W;
Above -10F 10W
Transmission: 1-1/4 Pint
Grade of Oil: Summer 90, Winter 90
Rear Axle: 1-1/4 Pints
Grade of Oil: Summer 90, Winter 90
Beginning Engine Numbers: Model 48: 89001
Model 77: 1001
Beginning Serial Numbers:
Brake Specifications, Model 48
Lining Material: Primary Shoe: Molded; Secondary Shoe, Woven.
Lining Dimensions/Wheel in Inches: 19-3/16"
Width: 1-3/4",
Thickness: 5/32"
Pedal Free Play: 1/2"
Brake Specifications, Model 77
Lining Material: Primary Shoe: Molded; Secondary Shoe, Woven.
Lining Dimensions/Wheel in Inches:
Front Wheel: 18-13/16"
Rear Wheel: 16-3/8"
Width: 1-3/4",
Thickness: 5/32"
Pedal Free Play: 1/2"
Wheel Alignment Specifications
Caster: +3 Degrees
Camber: +2 Degrees
Toe In; 3/32"
Kingpin Angle: 7-1/2 Degrees
Rear Axle Data
Ring Gear & Pinion Backlash: .004"-.008"
Drive Pinion Adjustment: Shims
Drive Pinion Bearing Adjustment: Shims
Axle Shaft End Play: .004"-.006"
Auto-Lite Distributor Specifications:
Distributor #1GS-4007B
Cam Angle: 47 Degrees
Breaker Point Opening: .020"
Condenser Capacity: .20-.25 Mfds
Breaker Arm Spring Tension: 17-20 Ounces
Centrifugal Advance Data:
Advance Starts: 2 Degrees @ 550 RPM
Full Advance: 9-1/2 Degrees @ 1,500 RPM
Vacuum Advance Data:
Advance Starts: 1 Degree @ 6-1/2" Vacuum
Full Advance: 7 Degrees @ 15" Vacuum
Distributor #1GW-4129
Cam Angle: 41 Degrees
Breaker Point Opening: .020"
Condenser Capacity: .20-.25 Mfds
Breaker Arm Spring Tension: 17-20 Ounces
Centrifugal Advance Data:
Advance Starts: 2 Degrees @ 550 RPM
Full Advance: 9-1/2 Degrees @ 1,500 RPM
Vacuum Advance Data:
Advance Starts: 2 Degrees @ 5-3/4" Vacuum
Full Advance: 10 Degrees @ 15" Vacuum
Auto-Lite Generator Specifications:
Generator #GAM-4504A
Brush Spring Tension:
Main: 18-22 Ounces
Third: 18-22 Ounces
Direction of Rotation: Clockwise
Field Current at 6 Volts: 3.89-4.31 Amperes
Low Output Test: 8 Amperes, 8 Volts @ 1,070 RPM
Maximum Output: 17.5 Amperes, 8 Volts
Generator #GAM-4504B
Brush Spring Tension:
Main: 18-22 Ounces
Third: 18-22 Ounces
Direction of Rotation: Clockwise
Field Current at 6 Volts: 3.89-4.31 Amperes
Low Output Test: 8 Amperes, 8 Volts @ 1,070 RPM
Maximum Output: 17.5 Amperes, 8 Volts
Generator #GBM-4612A
Brush Spring Tension:
Main: 50-60 Ounces
Third: 50-60 Ounces
Direction of Rotation: Clockwise
Field Current at 6 Volts: 3.80-4.20 Amperes
Low Output Test: 8 Amperes, 7.6 Volts @ 1,250 RPM
Maximum Output: 21 Amperes, 8 Volts
Generator #GCJ-4811A
Brush Spring Tension:
Main: 53 Ounces (Maximum)
Third: 53 Ounces (Maximum)
Direction of Rotation: Clockwise
Field Current at 6 Volts: 1.90-2.10 Amperes
Low Output Test: 8 Amperes, 8 Volts @ 1,135 RPM
Maximum Output: 26 Amperes, 8 Volts
Auto-Lite Regulator Specifications:
Regulator Type: Regulated by Third Brush
Regulator Number: CB-4025
Armature Air Gap: .010" to .030"
Point Gap: .015" to .045"
Voltage to Close Points: 6.5-7.25
Amperage to Open Relay Points: 0.5-2.5
Maximum Operating Amperage: 15 Amperes
Regulator Type: Voltage
Regulator Number: VRD-4004A
Ground Polarity: Negative
Voltage to Close Points: 6.4-7.0
Amperage to Open Relay Points: 0.5-3.0
Maximum Operating Amperage: 15 Amperes
Maximum Operating Voltage:
Before #8R-000001: 7.65 Volts
#8R-000001 & Later: 7.45 Volts
Auto-Lite Starting Motor Specifications:
Unit #: MZ-4049
Brush Spring Tension: 42-53 Ounces
No Load Test:
70 Amperes; 5.5 Volts; @ 4,300 RPM
Lock Test:
560 Amperes; 4.0 Volts; Torque 11.8 Ft Lbs
Unit #: MZ-4064
Brush Spring Tension: 42-53 Ounces
No Load Test:
70 Amperes; 5.5 Volts; @ 4,300 RPM
Lock Test:
560 Amperes; 4.0 Volts; Torque 11.8 Ft Lbs
Tillitson Carburetor Adjustments:
Idle Screw: 1 Turn Open
Main Adjustment: -3/8 Turns Open
Fuel Level: 3/4" below upper rim of float bowl.
Fuel Pump Data:
Pump Model: AF
Maximum Pressure: 3 PSI
Dash Gauge Manufacturers:
Gasoline: King-Seeley
Temperature: King-Seeley
Oil Pressure: King-Seeley
Ammeter: King-Seeley
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