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Poppet balls, springs and caps

Poppet balls, springs and caps
DLane

DLane

Jeeper
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Location
Edmonton, AB
Vehicle(s)
1974 CJ-5, Chevy 305 w/ Turbo 400 trans
Started rebuilding my Dana 20 t case. Have the crown rebuild kit and realized as I was tearing it down my t case is missing the poppet balls, springs and caps. Anyone have thoughts where to get them? Checked most of the favorite sites and nothing listed...
 
DLane said:
Started rebuilding my Dana 20 t case. Have the crown rebuild kit and realized as I was tearing it down my t case is missing the poppet balls, springs and caps. Anyone have thoughts where to get them? Checked most of the favorite sites and nothing listed...
Click to expand...

I just looked at this site:
Parts for the Jeep & IH Dana 20 Transfer Cases

using poppet balls as a search phrase.

The Novak people answer their phones when they are open, and will answer your questions, I'm sure.
 
Ill contact them and see if they will sell poppet ball and spring separate. Would have gotten a full rebuild kit like this in the first place but didnt realize I was even missing them.
 
Thats weird. I thought my kit from Crown came with those. It might have been the Novak kit I bought a week later though.

Be careful with the intermediate shaft in the Crown kit. Mine was .006-.008" oversize and I didn't realize this until it was too late as it was my first rebuild. Bought the Novak kit since Crown and 4 wheel parts basically called me a liar. More expensive but clearly better quality.
 
Ill be sure to check the intermediate shaft. Worst case I still have the original in good shape.
 
so turns out the balls were in my crown rebuild kit, and found the springs on quadratec. Can anyone post a picture of the caps? Thinking i could just use a bolt the right length if i cannot find any replacements.
 
Your tcase doesnt have the caps in it?

If you can get them out carefully you can just silicone them and reuse them.

They are alot longer than youd expect so check your kit again. If a 1/2" is sticking out of the tcase, an inch of the cap is inside the tcase.
 
All I have is two threaded holes, and that's it. No caps or bolts or anything in the t case or the rebuild kit :(
 
Those threaded holes are for the low range and 4WD. light switches if you jeep uses them. As for any uncapped holes I just cut a metal patch and siliconed them in place. (but don't fill the holes with the silicone.)
 
The caps are on the opposite end of the shift rods. There should be something there. If you havent disassembled yet they might be covered in grease and you arent seeing them.
 
I have the caps on the end of the shift rails, 2 press in caps roughly 1/2" diameter but I'm talking about whatever holds the poppet balls and springs in on the topside of the shift rails towards the front of the t case. Ill post a picture tomorrow to clear up any confusion.
 
I think when Dana shipped these to the assembly plant they had a plastic plug installed like an NPT port on an air or hydraulic cylinder. They should have been removed and either a switch or a threaded plug installed. Unfortunately, it seems as the majority came out with the temporary plug still installed. I have a 1978 that had the plastic plugs and a 1979 that has the steel threaded plugs. I don't think they are available even though I was on a Bronco site years back that had some listed. I haven't been able to find it again. The thread is 9/16-18 which is (even though a standard thread) hard to find.
 
rrekr said:
I think when Dana shipped these to the assembly plant they had a plastic plug installed like an NPT port on an air or hydraulic cylinder. They should have been removed and either a switch or a threaded plug installed. Unfortunately, it seems as the majority came out with the temporary plug still installed. I have a 1978 that had the plastic plugs and a 1979 that has the steel threaded plugs. I don't think they are available even though I was on a Bronco site years back that had some listed. I haven't been able to find it again. The thread is 9/16-18 which is (even though a standard thread) hard to find.
Click to expand...

Well at least I have a size and thread to go off now. Thanks very much. Once I get the springs I can roughly figure a size and see what's going to work.
 
The springs and detent balls go (as you know) below the shift rails. They have no bearing on the length of the the plug you need. You will need a 9/16-18 plug less than 1/2" under head length to do what you are trying to do. I gave up looking and made my own.
 
Just had a duh moment before I read this ^^^ as I just got the rails out and look at that, poppet balls and springs under the shift rail... I had figured they went on top and the bolts or caps I was looking for held them in place. So now just to plug the top side however I can make work! Shows how easy it is to get confused when you don't know what your talking about.
 
DLane said:
Just had a duh moment
Click to expand...
Don't be so hard on yourself I think it's called a learning experience. It happens when you do something you have never done before.
 
I always wondered what the plastic plugs were on mine until I rebuilt it. Lasted 30 yrs though.
 
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