Dana 20 Refurb

[wilsonasantos10]

I've started a re-furb of my twin stick Dana 20 tcase. So far, I've pulled out the rear yoke + gears and the intermediate shaft / gears / bearings / washers. Front yoke is forthcoming, then I can pull out the rest of the stuff.

I have a couple questions that you more experienced fellas may be able to help me on. Attached are a handful of pictures of the gears.

Note the black marks on the intermediate gear. The marks are fairly "crusty" and resistant to scraping off - I just ran a flat head screwdriver over them very briefly and nothing came off. Should I replace the whole intermediate gear? Or keep it and try to clean it? If you think it can be cleaned up, how do you recommend doing it?

The rear output yoke + the mainshaft gear assembly has ZERO play in it...very tight. I don't think I'll disassemble this. Opinions?

Any opinions on the condition of the front output gears based on the pictures?

 

[hagar]

Appears to have had water inside at one time.
Wouldn't be an issue to re-use it based on what I see.
Wear on sliding gear is normal.
If these are still Dana gears, I'd be re-using them.

 

[wilsonasantos10]

I had a different thread open under "Twin Stick Tcase Noise" prior to dropping the Transfer Case and starting this new thread. I think I found the source of the grinding / rattling. It only occurred in 4 Lo on the front shaft. As you can see from the pictures, the Front Output Shaft Sliding Gear was coming into contact with the case and grinding a groove into the case. I think the case is fine as there's no cracking or holes. And I don't see any glaring problems with the gear. I wonder what could have caused this. I'll rebuild the whole front output gear assembly and hope that it solves the problem.

 

[wilsonasantos10]

I'm driving myself crazy trying to get the front bearing off of the front output shaft. I've got it rigged up similar to the article on pirate 4x4 with a bearing separator and clamps on the case, driving the shaft towards the rear and separating the bearing from the shaft. I'm banging on it and it doesn't want to budge!! I don't have a press so I'm at my wits end. Anyone in Spring, Texas have a press I could borrow??!!

 

[CJ]

I'm driving myself crazy trying to get the front bearing off of the front output shaft. I've got it rigged up similar to the article on pirate 4x4 with a bearing separator and clamps on the case, driving the shaft towards the rear and separating the bearing from the shaft. I'm banging on it and it doesn't want to budge!! I don't have a press so I'm at my wits end. Anyone in Spring, Texas have a press I could borrow??!!

You cannot beat off the pressed on bearings. You can head over to a machine shop and or a small fee they will press them off and the ones on.

My Dana 20 pics are here -->> https://www.jeep-cj.com/gallery/browseimages.php?c=21

And using my press pics are below.

 

[wilsonasantos10]

Well that is great to know! Thank you. I guess for some people it works for whatever reason. I’ll get em pressed out.

 

[wilsonasantos10]

The front main shaft, main shaft gear, sliding gear, and front bearing are still assembled and inside the case. I don’t think I have a snap ring by the main gear, pretty sure it’s a thrust washer but not certain. Am I to press the front bearing off of the shaft while it’s still in the case and then I’m assuming I’ll be able to remove the washer and gears?

 

[CJ]

The front main shaft, main shaft gear, sliding gear, and front bearing are still assembled and inside the case. I don’t think I have a snap ring by the main gear, pretty sure it’s a thrust washer but not certain. Am I to press the front bearing off of the shaft while it’s still in the case and then I’m assuming I’ll be able to remove the washer and gears?

Can you post a pic?

 

[wilsonasantos10]

Here you go. Hope this helps.

 

[wilsonasantos10]

I think I figured out why the front shaft sliding gear has scraped a gash into the case. Look at the orientation of the sliding gear in the pictures I've posted - specifically the shift fork location. I think the PO installed the sliding gear backwards. If it was flipped around the other way, the channel on the sliding gear where the shift fork attaches would prevent the sliding gear from coming into contact with the case.

 

[wilsonasantos10]

I've got everything put back together and no more sliding gear grinding on the case from the PO!

How do are these poppet balls and springs supposed to fit? The length of the fully compressed spring, plus the ball, plus the threaded end of the screw, there's just not enough space in that hole to fit it all!

 

[CJ]

I've got everything put back together and no more sliding gear grinding on the case from the PO!

How do are these poppet balls and springs supposed to fit? The length of the fully compressed spring, plus the ball, plus the threaded end of the screw, there's just not enough space in that hole to fit it all!

It's a tight squeeze but they fit. See -->> https://www.novak-adapt.com/knowledge/transfer-cases/rebuild-guides/dana-20-rebuild-guide/

 

[wilsonasantos10]

Any recommendations / best practices on how to squeeze it all in there? Mind you that my shift rails are currently installed as well.

I fully compressed the spring and measured it with the poppet ball and the threaded end of the screw...its longer than the hole itself.

sorry...newb learning here!

 

[CJ]

Any recommendations / best practices on how to squeeze it all in there? Mind you that my shift rails are currently installed as well.

I fully compressed the spring and measured it with the poppet ball and the threaded end of the screw...its longer than the hole itself.

sorry...newb learning here!

Is this the original equipment? If so, it will fit.

 

[algmmech]

The springs and balls go under the shift rails. Not on top.