Dana 20 pouring oil

Still tightening up nuts and bolts since the Jeep is on the road. I have a leaky Dana 20, and when I say leaky I mean it is pouring oil out. The leak is where the Texas pattern is located where it bolts to the T18 spacer. The oil is definitely leaking on the Dana 20 side since I just added a quart of oil to it since discovering the leak. I tightened the bolts, cleaned it up really well and went for a ride to get it warmed up. When I got back I can see that the leak is coming from near Houston.

I think I'm going to have to un-mate the TC and T18 and put in a different gasket. Before I do, I wanted to check with you experts to see if this is the most likely culprit, and what else I should be looking at while I'm there.

Thanks.

 

I would redo, it is likely torn. or the thread areas are pulled out from the casting.

use some studs during disassemble and take a flashlight before you get too far so you can find something silly before the heavy lifting,
I used 2 3" bolts with the head cut off and rounded one shorter then the other. also cut a screwdriver slot on the end. then do the same using shorter bolts so you have one hole to hit while lifting and align the rest one at a time. I also put rtv on both sides of the gasket, with that and studs the gasket won't go anywhere while you slide everything together. just replace the bolts one at a time, then torque to spec.

 

Thanks for the stud idea, that should make it easier on me. I'm thinking of going with just RTV at this point, probably just as good as a gasket and easier/faster to find.

 

Yep sounds like you have to remove the t case and get a new gasket

 

Use a gasket as well as a THIN coat of rtv on both sides. The gasket acts as a shim setting clearances. Plus, too much rtv and the excess eventually breaks off and plugs oiling passages. Seen it too many times......


Sent from my iPhone using Tapatalk

 

If its a Novak adapter? they told me I didnt need the gasket as a shim. When I did a T18/T19 in a 74.
I had issues getting it to seal up! I had to remove the D20 twice and take a little metal off the adapter to clearance.
I used black RTV and everything worked great.

 

I did not even realize that there was even supposed to be a gasket there. when i mated my scout dana 300 i just used right stuff and have not had a drip one from that area.

 

The gasket does act as a shim. It helps keep the input gear in alignment with the other gears and insures the right clearance between the input gear and output shaft.


Sent from my iPhone using Tapatalk

 

Thanks Nick, I didn't think of the RTV plugging oil passages etc.

The texas pattern gasket is not something I've been able to find at a local supplier. I'm thinking of making my own with the rolled gasket material I've seen, unless someone can tell me a part number to use at the local part store.

 

I've always made my own with a sheet of paper gasket material and a ball peen hammer. Then I smear both sides of the gasket with grease to help it stick to the mating surfaces.

 

I remember those days....

 

I still do this, mainly because I know its going to fit when I am done. Seems to be a bit of a lost art.

 

I ordered 2 pre-made gaskets (I want some redundancy in case I screw one of them up). However, I will also be making my own just see if I can. The one with the most quality goes on the TC.

 

where did you order them from?

 

My favorite Jeep part supplier...Oconee Offroad, it's an Omix part but at least I didn't have to buy the whole seal kit to get one gasket.

here's the link:

http://www.oconeeoffroad.com/servlet/the-32860/omix-dsh-ada-18603.57-GASKET%2C-TRANSM/Detail

Can't comment on quality yet since I haven't received it.

On another note. I might not even need it. As I was getting ready to remove the TC I found that the upper and lower bolts on the right side were loose. I decided to tighten them down, replace the driveshafts and go for a spin to see how much it leaked (notice I didn't say "stop the leak"). It's still dripping out, but not nearly where it was. The gasket might be damaged just from the bolt being loose and the TC vibrating against it, I don't know. I'll watch it for a bit before deciding on dropping it for a gasket change.

Edited to add: I'm finding that this is an issue with my build going on for 6 years...I start something, get interrupted or distracted, and maybe forget I didn't do something, like tighten down two bolts...and voila! I have a leaky TC.

 

For as many times as I've removed/reinstalled my t-case in the past 13 years I've never used anything but black RTV w/o issues. When I swap out my T-15 for T-18a I'll continue to use it sans gasket. [/crankyoldman]

 

To close the thread out with the solution...

I dropped the transfer case today, peeled off the old gasket, and installed a new one. I did not find any tears or rips on the old gasket so I'm not exactly sure why it was leaking. When I installed the new one I used Hylomar HPF to coat each side lightly. I also made a couple of studs per jwjeep's suggestion, worked like a charm when I was lifting the TC back into place, sans jack.

Went for a test ride for about 20 miles of stop and go...and it's dry as a bone! FWIW, the Omix gasket fit right and seemed like a good quality. Here's a pic with part number if anyone needs one sometime. Got mine from oconeeoffroad for about $4.