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Dana 20 Rebuild

Discussion in 'Intermediate CJ-5/6/7/8' started by AlexCold, Oct 29, 2016.

  1. Oct 29, 2016
    AlexCold

    AlexCold Member

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    Does anyone know the best/simplest method for removing the front output bearing on a Dana 20?

    I found this method on the Pirate4x4 site (Pirate4x4.Com - Extreme Four Wheel Drive) which worked for the rear output but I don't have the proper splitter for the front. Here you clamp the spitter to the case and pound the shaft through.

    FYI, these photos are from the link above not from my actual transfer cae.

    [​IMG]

    [​IMG]

    Does anyone have any other ideas?
     
    Last edited: Oct 31, 2016
  2. Oct 30, 2016
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    You're trying to push the shaft out the wrong way. You're fighting the gear which is bottoming against the case. Try the other direction.
     
  3. Oct 30, 2016
    AlexCold

    AlexCold Member

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    How so? I'm currently trying to push the shaft out the back of the transfer case. I can't push it through forward.
     
  4. Oct 30, 2016
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    Oops, I jumped a step ahead and it looked like in the second pic the gear was bottomed on the case. That's what happens when I stay up too late:(
    I've had to use a small chisel as a wedge to get in between the thrust washer for the small gear and the bearing to get the bearing to move. Once it starts moving it will come out easier. You usually damage the thrust washer but at least you can get it apart. You may have to start in one spot, rotate the shaft and try again, rotate it again, etc. and work around it until the bearing starts to move. After the bearing is removed double check that yours does not have a snap ring holding the thrust washer and gear on. Some did, some didn't depending on vintage and application.

    If you ending up bunging up the thrust washer and need one, let me know. I probably have one laying around in my transfer case parts drawer.
     
  5. Oct 31, 2016
    AlexCold

    AlexCold Member

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    Looks like I found another method on this build (which looks kind of cool too!) Teralow for the Dana 20 Transfer case - Project-CJ7

    I'll try it when I get home. [edit] I used this method and it works great. Takes more force than you'd think but as long as you don't have a snap ring there, it will come right out. No special tool required.

    [​IMG]
     
    Last edited: Nov 2, 2016
  6. Oct 31, 2016
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    Make sure there isn't a snap ring between the thrust washer and bearing before you try that. If there is a snap ring doing that will only damage parts.
     
  7. Nov 1, 2016
    AlexCold

    AlexCold Member

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    I did not see one, but I will look again and post a picture. I only saw what looked like a thick washer.
     
  8. Nov 1, 2016
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
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    If there is one you should be able to see it with a flashlight as it will make a small gap between the bearing inner race and the washer.
     
  9. Nov 2, 2016
    AlexCold

    AlexCold Member

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    Nope there is not one. I was able this morning to get the shaft out by using the method just above. It took some gusto but it got the job done. Shaft and gears all look good.
     
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