Dana20 rebuild

Hi.


I started to rebuild a project Dana20 that I am planning to put in my-56 CJ5.
When I bought it it was full off water so i need to totally disassemble it.

Thanks to the great advise on Novak web pages i was able to get this far



But now i am stuck and need help.Can someone please explain how can i take appart
the gears and bearings from the front output shaft.

This is the first time(total newbie) i am rebuilding the transfer case so please adwise
on even the obvious things.

And for those who will suggest that i should just get a better one from junkyard, i need to tell that i am from
Finland Scandinavia and that won't be an option.

 

If I recall correctly you tap on the output shaft carefully so as not to damage threads. This drives the bearing out and allows the shaft to be removed.

 

Yep, I did that and now the saft is loose from the case itself but the problem remains.



I still need to get the bearings of the shaft, How do i do that without breaking anything ?

 

I've rebuild a Dana18, but not a Dana20, this might (or might not) be useful:

http://www.classicbroncos.com/dana20/dana_20_manual.htm

 

I am planning on using SBC 350 and TH350 combo . So wanted to go with a little bit beefier
axles than than the c-clip D44 it used to have.

Luckily I got was able get transfer case , drive shafts, and front and back axles from the same donor jeep.
so i do have the correct rear Dana 44.

That rear axle was actually the reason why I needed the Dana20 as well.

 

Thank you for the link.

I did read the instructions again , but still i am not getting it.



--snip

16. Wedge the front output shaft front bearing away from the main drive gear to allow removal of the snap ring from its groove in the shaft. Then, tap the shaft and rear bearing out of the case (Fig. 8).

[Editor’s note: Your J-shift case MAY NOT have the aforementioned c-clip on the front drive output shaft in between the bearing cone and the high speed drive gear. If not, note that the front bearing cone is mildly pressed onto the shaft at the splined area. You are able to CAREFULLY (with a light hammer and a soft drift) tap the shaft assembly toward the rear of the case, driving the front bearing cone off the shaft. You can now remove the shaft assembly.
--snip

I just can not see a snap ring anywhere, and i can not wedge the front bearing away from the gear.

Could it be a factor that this particular D20 is the -65 to 74 model with 10 spline input ?

most of the instructions i have found are for the earlier version or the Bronco version of D20.

 

I believe I was able to pry the bearing off the shaft. I think I used a Pickle fork.

 

That is described in the dana 18 rebuild guide:

http://www.willystech.com/wt/Model18TCase/Model18TransferCase.html





I used a pickle fork too.

 

I'm thinking if you drive the shaft the other direction it will press the bearing cup out giving more room. Maybe this pic helps.

 

I recall I did not have a lot of trouble with this - didn't need an axe! :smash:

It's been too long fro me to remember the details though.

This might be helpful:
http://offroaders.com/info/tech-corner/project-cj7/Teralow-Dana20-project-cj7.htm

 

Yes, that sounds right. Something like that.

 

OK, I will give that a try.

 

There's a good picture in that article I linked.

 

I did mine last summer and you dont need the axe thing.
thats for the 18 case.

I used a gear puller if I remember right.

 

Two small flat chisels. One on each side between the bearing and the shaft. Once you get it to move you can use larger chisels carefully or a couple of pry bars. There are some model 20's that use a snap ring behind the bearing very similar to the 18. I've mostly run into them from early Bronco's and Scouts. Yours may or may not have one. If it had a spacer between the yoke and the bearing then it shouldn't have a snap ring. Once that bearing is off the shaft will slide out the rear of the case. If you can tell for sure it doesn't have a snap ring you can carefully drive the shaft out the back of the case.

 

Thank you all,

That did the trick



I just needed to use bigger hammer R)

 

LMAO @ myself though, sounds like something I'd do!R)