Dana 20 twin stick help

[Lumpy Grits]

Posi-Can you show us a picture when engaged in 2WD Low range?
LG

 

[Posi]

May not get to it until after this weekend.

 

[Hedgehog]

Posi - What kind of Transfer Case do you have? It isn't a Dana 20 from a CJ is it?

 

[Posi]

It's a Dana 300 . However, it has the same twin stick shift pattern as the Dana 20 , this is why I didn't mention it.

 

[Hedgehog]

I think I'm overly concerned with an apples to apples comparison.

Yours looks aluminum and I didn't recall the Dana 300 as having aluminum castings so more than anything I was wondering what it was.

Edit: Did a google image search and there it is clear as day. An aluminum shift housing. It was 30 years ago that I did a Transmission switch with a Dana 300. Memory isn't as reliable as it should be.

 

[Posi]

The Dana 300 has an aluminum front cap, and cast iron case.









Twin stick shift patterns is the same between the 20 and 300. The 20 and 18 use a sliding gear and sliding clutch, the 300 use sliding clutch rings. Same shift pattern, same visual results.

 

[Hedgehog]

Very pretty, great photographs

 

[Hedgehog]

Took some pictures:

here she sits



In Rear 2wd low



High Rear WD



Some times it pays to go to a junk yard.



This started when I was asking what the flat spots on TOP of the shift rails were for. Come to find out they are to work with switches similar to the back up switch for reverse. They were used in some truck applications. While looking at the pile of Dana 20 t-cases at Willys Works one stood out. It had the above switch configuration where both the front WD & the rear WH shift rails were switched. I'm thinkin' cool, with the pills removed from my T20 this could be helpful. Since these switches are impossible to find Rob salvaged them for me. Even Rob wasn't sure if both shift rails had notches. I looked at mine and by god both rails are notched for switches. The following is how the notches are configured:

High Rear WD = off - Rear WH Neutral = on - Rear WD Low = on

Front WD Neutral = off - Front WD High = on - Front WD Low = on

I'm figuring to have two dash lights, Front WD and Rear WD. If the shifters are in any position other than High Rear Wheel Drive & Front Wheel Drive in neutral the lights will tell me somethings up. I think this will be a VERY cool addition to the CJ.

 

[Lumpy Grits]

Really like the useage of the Heim joints.
LG

 

[ksouthw80]

Ok so my parts will be here tuesday and i have not been able to pull the case yet and more than likely i wont be here to sign for the parts so i'll have to run around town on this one. i've got a busy week but i do plan to pull the case so we can see whats up. I'm not above being wrong so were going to look at this together. more than likely the fork is backwards , what else can it be. its definitely hitting solid. I want to know what the problem is even tho i am putting in a different kit. Looking fwd to finally getting it back on the road.

 

[Hedgehog]

Yes you do want to know so if there is a mistake it won't be made again. If the front when drive fork Allen screw is easy to get to, and toward the rear it's backwards. You'll notice that the fork is offset on the shift rail casting, that should be towards the front of the case. The big gear should be over (case upside down) the offset. ....no very clear I know, it's easy to see, but difficult to put in writing.

It might be easier on your end, I don't know how much leeway the UPS guy has on delivery. It might not be you that has to receive the package, I believe the note said that it had to be someone over 21 to receive the package. Your wife (or to be politically correct "Partner") might or should be able to sign for the package. Crazy, why I don't really know.

 

[ksouthw80]

Just got the case out.. keep in mind the problem i am having is that the tcase will not go into REAR LOW RANGE. Ok so the rear fork is hitting on a gear slightly. Forgive me for not being exact i have not had time to investigate and renew my memory for correct nomenclature of the parts i'm talking about. But in the mean time take a look at the pictures. Please let me know what you see. BTW Although i guess it has to be possible I dont see flipping the rear drive shift fork over. ????

 

[ksouthw80]

Its hitting at the area around the allen screw

 

[ksouthw80]

rear sliding gear is backwards

 

[ksouthw80]

A simple mistake on my part. Will be tearing it down and building it back up with the tera kit. This time much more carefully. Gonna dedicate a few evenings to get this done and installed.

 

[ksouthw80]

Maybe this will help someone some day. Its a simple mistake on my part and a 50/50 chance of making the same mistake. Possibly repairable with out pulling apart but I'm not thinking it out. Looking at the pic the gear on the far right is the rear drive gear and has the shift fork in the slot kinda like a belt on an alternator pulley,,, in my case and the pictures case IT IS BACKWARDS. Hey It is what it is... I rebuilt this and the the Transmission using the chiltons book and a print out . Look a lot further into these rebuilds than I did. Check out BillaVista.com for some good instruction and take it all into account unlike I did.

 

[gert]

Maybe this will help someone some day. Its a simple mistake on my part and a 50/50 chance of making the same mistake. Possibly repairable with out pulling apart but I'm not thinking it out. Looking at the pic the gear on the far right is the rear drive gear and has the shift fork in the slot kinda like a belt on an alternator pulley,,, in my case and the pictures case IT IS BACKWARDS. Hey It is what it is... I rebuilt this and the the transmission using the chiltons book and a print out . Look a lot further into these rebuilds than I did. Check out BillaVista.com for some good instruction and take it all into account unlike I did.

man thats a bummer but its pretty neat that you are getting to rebuild it as a 4 to 1 T case now tho

so you installed the gear itself back wards?

 

[CJ]

Maybe this will help someone some day. Its a simple mistake on my part and a 50/50 chance of making the same mistake. Possibly repairable with out pulling apart but I'm not thinking it out. Looking at the pic the gear on the far right is the rear drive gear and has the shift fork in the slot kinda like a belt on an alternator pulley,,, in my case and the pictures case IT IS BACKWARDS. Hey It is what it is... I rebuilt this and the the transmission using the chiltons book and a print out . Look a lot further into these rebuilds than I did. Check out BillaVista.com for some good instruction and take it all into account unlike I did.

You did good and figured it out, Dana 20 's are simple but just one little oops can fubar the rebuild. Glad you got it fixed.

 

[ksouthw80]

Yes the gear is backwards. The groove or slot is facing the rear of the case. It should face forward. Yes at least I know what the problem is and no harm was done to any of the parts or case. I am installing the tera kit this time.. At least its not a daily driver for me,,, I've been there before..

 

[JR74CJ5]

Good job figuring it out man. I rebuilt mine with the Novak kit and remember looking at everything when I had it all out going "uh oh..." lol but took my time and got it back together too.

I'm jealous of the 3 to 1 low kit man! That will be my next upgrade when I have the time to rip out the Transfer Case again. Actually, slightly after a few more pressing matters...