D20 twinstick pops out of gear

[73CJ]

I just put a twinstick on a Dana 20 Transfer Case . The rear axle pops out of gear under load. I put new detent springs in when I removed the 'pill'.

Anyone have any ideas?

 

[CJ]

What twinstick did you put on? I just purchased this one -->> Dana 20 Twin-Stick Kit but got it from Novak.

One of the reasons I purchased this tick is because of this statement. -->>
Provides a solidly-detented 2WD-LO position that WILL stay in gear

They have allot of trouble shooting information concerning jumping out of gear in a PDF. I attached it for you.
​

 

[73CJ]

CJ
Thanks for the site. I suspect it maybe wear on the detent groove. You can hold it in gear, but really gets hard under load.

 

[CJ]

So that is the same twin you purchased? Did you have any trouble keeping it in gear before?

 

[73CJ]

No it didn't pop out before. When I pulled the pill out I noticed the notches on the shafts were grooved from wear by the detent balls. Heavier detent springs or maybe tap a setscrew to crank up the spring pre-load?

 

[CJ]

Either one is worth a shot. I'd probably try a different spring first.