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When I pull my T-18Transmission and Dana 20Transfer Case out to do a flywheel and clutch I was contemplating rebuilding both. They leak so they could at least use new gaskets. I’m pretty mechanical but have never rebuilt transmissions or transfer cases. Was wondering for those out there...how hard is it?
I've dont both...Neither is very difficult, but a 2nd set of hands is very helpful, especially for the Transmission . Bearing, thrush washers, snap rings is about it. You will need a small bearing separator for the Transfer Case and some good snap ring pliers and a bigger bearing separator for the transmission. You will also need a dial indicator. And you'll need to ID which version of the T-18 you have.
Oh and if you want to go a little deeper with the low range, look up the 2.46 low range conversion. It uses a combination of Bronco D20 and Jeep D18 gears to get a 2.46 low range Jeep D20. The stock Jeep D20 is 2.02, that's a 22% reduction, which is about the same as going from 3.73s to 4.56. Parts can be tough to find though.
'79 Cj5, 258 with Howell Fuel injection kit, T18 with dana 20 Tcase, dana 30 front with Detroit locker, AMC 20 rear with LSD and one piece shafts, Warn 8k winch, 1" body lift, 2" suspension lift, 33 tires
I rebuilt my Dana 20 . It's not bad. As previously mentioned above some "specialty" tools are needed. If I remember there's only 3 gear sets in the Transfer Case . The hardest part for me was keeping the needle bearings and thrust washers in the middle gear while installing the shaft. I cut the o-ring the first time. The second hardest part, more of time consuming was setting the end play with the shims under the cover. Word of advise on this... dry fit until you get the end play you want, then seal it with RTV. Otherwise, there will be a big mess. And I double checked after I sealed it. Here's a good write up I used
It's not perfect but it's a very nicely written and picture write up.
As far as the Transmission , I have not done a T-18 but I did rebuild a NP435. Again, nothing to complicated. Take your time, take pictures and label things. Double check end plays and have fun. It's all a learning process. For me, I understand something more when I take it apart and see what actually goes on vs reading it. Best of luck!
