Common features

The DJ-5 models used by the United States Post Office had right-hand drive (without power steering), and were built in a lighter, less durable design than the standard Jeep. These changes included the use of C-channel frame rails (as opposed to the box rails of the CJ-5) and, while the hood was the same dimensions as (and interchangeable with) the CJ, it did not have the reinforced design of the original. The standard configuration had only a driver's seat and a letter tray installed. This decreased curb weight, combined with different leaf springs than other models, allowed carrying more cargo weight behind the driver.

Dashboard and interior of 1976 DJ-5D

The metal side doors were also designed to slide open and closed, and could be locked open while driving. They were supported by ball bearings, which ran in a channel just under the rain gutter, and a plastic retainer ran in a small channel along the body. A worn, damaged or lost retainer would allow the door to swing outward, fail to engage the rubber stop on the rear bumper, and slide completely off of the channel (and the vehicle). A single, hinged rear door gave access from the floor to the bottom of the hard top, and was the width of the open area between the wheel wells.

AM General used a variety of powerplants during production. DJ production was ended in 1984 with the DJ-5M, which used the 150 cu in (2.5 L) AMC straight-4 engine.

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  Jeep DJ-5 in USPS livery
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  DJ-5 in USPS livery
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  DJ-5 in post USPS use with elongated grille
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  DJ-5 in post USPS with large swinging rear door

DJ-5A

The DJ-5A was introduced in 1967, beginning the lettering system indicating changes within the series. As initially produced by Kaiser Co., the DJ-5A used a standard CJ front end, and was equipped with a four-cylinder Chevrolet 153 engine, shared with the contemporary Nova,^[12] and two-speed Powerglide automatic transmission, with a T-handle shifter located on the floor next to the driver's seat. The main body was a single unit, resembling the earlier Jeep when equipped with the metal Extreme Cold Weather Enclosure hard top.

There were no cutouts in the body for the rear wheels, which made tire changes more difficult, as even when the frame was jacked well off the ground, the axle did not fall enough for the tire to clear the body. The DJ-5A used standard 15-inch passenger car tires, with no provision for carrying a spare. While the front bumper was of the standard CJ design (though thinner and lighter than the original), the rear bumper was a unique design, a single stamped part that ran the full width of the vehicle. At each end was a rubber stopper for the sliding doors. The 10-gallon fuel tank was under the rear body, just ahead of the bumper.

DJ-5B

Close up of DJ-5 grille, with unique 5 slot design

After American Motors purchased Kaiser-Jeep in 1970, the AMC Straight-6 engine replaced the Chevy 153.^[12] In 1971, a unique five-slot grille without turn signals that was used only on postal Jeeps was introduced. The 1971 model actually has the grille extend past the front of the hood edge. This allowed more room for the larger engine and radiator. Like the DJ-5A, while resembling the CJ series, these were built as a completely enclosed, rear-wheel drive vehicle, with sliding side doors (which could be opened while driving), and a swinging rear door. Most models only had the driver's seat and a mail tray where the second seat would normally be located. One improvement over earlier Jeeps was mounting the rear springs outside of the frame rails, thus providing greater stability for the vehicle with its top-heavy enclosed cargo area, especially at highway speeds. Most models were also equipped with a limited slip differential and a heavy-duty steering gearbox. Other improvements include a vent in the roof and cut-outs around the rear tires.

DJ-5E Electruck

DJ-5E Electruck in USPS livery at NASA's Glenn Research Center

American Motors experimented with electric vehicles and starting in 1974 mass-produced the DJ-5E, a rear-wheel drive electric delivery van, also known as the Electruck.^[15]

Similar in appearance and in most of its dimensions, the DJ-5E was powered by a set of two 27-volt lead-acid batteries with a 54-volt 30 bhp (22 kW; 30 PS) compound wound DC motor with electronic regulation made by Gould Electronics.^[16] The U.S. Postal Service purchased 352 vehicles for the use in cities with serious air pollution.^[17] The Electruck was capable of cruising at 33 mph (53 km/h) with a range of 29 mi (47 km) with 20% of its battery power still remaining in reserve.^[17]