Can't get shift rods out of Dana 20 transfer case

[40YearOldCJ]

I am in the process of tearing down my Dana 20 and cant get the shift rods out. There is not enough room to loosen the set screw to remove the shift fork and pull the whole cap off with the rods in it. The rods also don't seem to move once you get them to a certain point. They basically won't pull or tap out, at least with the amount of force that I have applied so far. The shaft also wont rotate so I can't get better access to the set screw.

 

[jp360cj]

Rotate the rod that doesn't have the fork on it 1/4 turn (I don't think it matter which way) and it should tap out fairly easily towards to the front of the case. Be careful when it's almost out because there is a detent ball under spring pressure and it can shoot out when you pull the rod out. I would put a rag over the hole in the front housing above the fork (the one that usually has plastic plugs from the factory) and put another rag in the shift fork hole inside the case. Then you will have room to rotate the other rod to remove the fork.

Here's a great write up with pictures from Billivista: BillaVista.com-Teraflex Dana 20 Transfer Case Rebuild Tech Article by BillaVista

 

[40YearOldCJ]

Rotate the rod that doesn't have the fork on it 1/4 turn (I don't think it matter which way) and it should tap out fairly easily towards to the front of the case. Be careful when it's almost out because there is a detent ball under spring pressure and it can shoot out when you pull the rod out. I would put a rag over the hole in the front housing above the fork (the one that usually has plastic plugs from the factory) and put another rag in the shift fork hole inside the case. Then you will have room to rotate the other rod to remove the fork.

Here's a great write up with pictures from Billivista: BillaVista.com-Teraflex Dana 20 Transfer Case Rebuild Tech Article by BillaVista

Thanks! I was able to get them out. Seems like it might be fun trying to get them back in with the spring and ball.

 

[jp360cj]

Thanks! I was able to get them out. Seems like it might be fun trying to get them back in with the spring and ball.

Oh it is. I send one flying trying to get them back in.