DANA 20 2.46 gear swap?

[elkgroveguy]

Does anyone know of a place to buy these gears used or new?
I cant find the parts out there like everyone says to.
At least here in Northern California there are no used bronco transfer cases to be had, and no used Dana 18 cases that are not completely destroyed.
My other option is to go with the 3.15 gear sets but they all cost over $1,000!
I really dont want to spend more than $400-$500 including rebuild kit for my Dana 20 (leaks some oil).
Any info or help would be great.
Thanks

 

[jafo]

I was thinking Novak had the low gear kits for Dana 20 's for 800 and some change. I found a Dana 300 for 200 and decided to go with that. It had a lower gear ratio than the Dana 20 in stock forms. Not a lot but still lower. Was going to do a lomax 4:1 gear swap as JB conversions has those kits for 650. Much less than the tera flex novak sells for the Dana 300 . I'd find me a Dana 300 and if you want the crawling gears, get a set from jb's. Plus most conversion suppliers offer other upgrades for that Transfer Case . To me it's just a more economical way to go in the end. Jb's seems to have the lower prices. I'm sure the other brand will do the job, just a matter of what flavor you like. The Dana 300 will also require a conversion kit. Don't know what Transmission you run. If it's a T-150 , there is no conversion for that to a Dana 300 . T-18 , np435 and a few others they have the conversion kits for. So in the end I guess it wouldn't be more economical, just a few more add on options for the Dana 300 maybe.

 

[jafo]

Short answer, just come to mind. You might try calling Allstate Gear. I haven't looked, but they may or may not have replacement gears for a d18. Just have to look.

 

[elkgroveguy]

I like the Dana 20 because of how small it is.
It hangs down less and is shorter than the Dana 300
(which on my CJ5 I already have a short rear drive shaft)
Plus if I was to switch to a Dana 300 I would have to buy a Dana 300 with shifters, then get my rear drive shaft shortened.
It is a option, and if I had access to all the parts for cheap I might consider it but for now I would rather change the gears in my Dana 20 .
Thank you for the info and insight!

 

[jp360cj]

I just finished this swap myself (gears installed in tcase but tcase not back in Jeep yet).

Keep a check on ebay for the individual gears on eBay. I picked up the Bronco rear sliding gear for $43. I lucked up and found a complete D18 on eBay also and got it for $100 shipped!

Bronco graveyard (online) lists used gears. The rear slider is also $200, but the intermediate gear and front output gear are very reasonable. There are a couple vintage/Willys jeep sites that list gears also.

It should be a noticeable difference in the low range (I hope so at least). Going from the 2.02 to 2.46 low range is equivalent to going from a 4.10 (what I have) to a 5.00:1 axle gear. Or from a 3.73 to a 4.56. And can be done pretty cheap.

 

[Posi]

Does anyone know of a place to buy these gears used or new?
I cant find the parts out there like everyone says to.
At least here in Northern California there are no used bronco transfer cases to be had, and no used Dana 18 cases that are not completely destroyed.
My other option is to go with the 3.15 gear sets but they all cost over $1,000!
I really dont want to spend more than $400-$500 including rebuild kit for my Dana 20 (leaks some oil).
Any info or help would be great.
Thanks

You will need the bronco bull gear with the D-18 gears to get the 2.46 to work in your Dana 20 case.
I have the correct bronco bull gear.
I have the D-18 gears as well.

I'm not ready to give up my bull gear, not too many around.
The Bronco graveyard use to sell the bull gear for $100 not sure if they still have them, been awhile.
Take a lot around.
https://broncograveyard.com/

I may be willing to let my D-18 gears go if you can find the bull gear.

Be careful, there is some incorrect bull gear part numbers floating around the internet. I'll see if I can dig up a pics of my gear with the correct numbers.

 

[jp360cj]

You will need the bronco bull gear with the D-18 gears to get the 2.46 to work in your Dana 20 case.
I have the correct bronco bull gear.
I have the D-18 gears as well.

I'm not ready to give up my bull gear, not too many around.
The Bronco graveyard use to sell the bull gear for $100 not sure if they still have them, been awhile.
Take a lot around.
https://broncograveyard.com/

I may be willing to let my D-18 gears go if you can find the bull gear.

Be careful, there is some incorrect bull gear part numbers floating around the internet. I'll see if I can dig up a pics of my gear with the correct numbers.

From what I can tell, you can use either a Bronco bull gear (I think it's 18-8-33) or a D18 bull gear 18-8-23.

 

[Posi]

From what I can tell, you can use either a Bronco bull gear (I think it's 18-8-33) or a D18 bull gear 18-8-23.

The D18 18-8-23 is a 29 tooth helicut input gear.
The bronco rear sliding gear is 33 tooth, and has straight cut teeth.

Can't be interchanged.

 

[jp360cj]

The D18 18-8-23 is a 29 tooth helicut input gear.
The bronco rear sliding gear is 33 tooth, and has straight cut teeth.

Can't be interchanged.

I've always heard the input gear referred to as a bull gear, so I was a bit confused. But absolutely the Bronco rear slider 18-8-37 is the only gear that isn't available in any other case, and is nearly impossible to find. I don't know if they had any in stock, but broncograveyard was showing used ones for almost $200 a few months ago when I was looking. I got lucky on mine, but I also watched eBay for almost 2 months before it popped up.

 

[Posi]

After a day of wheeling my 54 3b I was driving home when I noticed a cop was following me. He followed me into my driveway.
Turns out he was an old Bronco guy and we talked for over an hour.
A week later he shows up at my door and hands me a Bronco 33 tooth gear.
Doesn’t get any better then that.
Since that time he stops by my shop in warmer weather to chat.
It been several years ago since he gave me the gear.

 

[elkgroveguy]

Well thanks for all the info guys!
From what im hearing, It might not cost that much more for me to get the custom gear set (3.15)
I just have a hard time paying $200 for a used single gear!
I have another question one of you may have an answer for?
my jeep has a AMC 258 i6 / 4.2l with a 4 spd.
and its a 1979, do I have a T-18 and would it be the one with the low 1st gear?
My first gear feels kind of crazy slow!

 

[Posi]

If it’s a stock 4 speed it would be the T-18 with a 6:32 first gear reverse over to the right and down.

 

[elkgroveguy]

Yes reverse is over to the right and down.
At least I have a good low first gear.
With 33" and stock 3.5? gears it drives great around town and cruises well on the freeway. That is why I would rather change the Transfer Case gears not the axle gears.