Dana 20 Removal

Ok, I have got to remove the Dana 20 to rebuild it, i cannot get it to shift at all and read some where it needs to be in neutral ! Not sure if that is correct or not, planning on leaving tranny in place and just drop transfer case, so question is steps to go about doing this. Cannot find anything online, what connects transfer case to tranny?

 

what transmission is in front of it

 

As I recall, it just slides off the transmission output gear. Nothing in the TSM saying it must be in neutral. I looked at the '75 TSM ... what year, model and equipment is this? It's important to include that info every time you ask a question. You can put that info in your signature file and it will be included with every post.

Ok, looking at your profile, it's a '72.




I recommend you purchase the '72 TSM if you have not.

 

Dowel pins? To keep it aligned while removing?

 

What Jeep recommends. I would use a couple of bolts with the heads cut off. Would be handy to help you slide it on and off of the output gear.

Last time I did this in my driveway I muscled the D20 and T-14 down by hand, using the factory screw jack to support the bell. Much younger and significantly more foolish then. No dowel pins.

Later manuals also require that you retain the current indexing of the propeller shafts wrt the yokes. Mark for reassembly.

 

Did mine last year - also a 72 with D20 on a T15. The gasket is the “Texas” pattern. Getting to the bolt I called “Texarkana” was the main issue I had and the hardest part of the whole rebuild for me. It’s tucked on the top of the case way under the access panel. The best way to get to it was to remove the cross member and tilt the whole engine/transmission/T-case assembly down to make enough room to get a u-joint socket on it. The TSM was helpful, especially with the idea for all thread dowels to support it when the bolts come out. Faxon Auto Literature has new reprints for a reasonable price and great customer service.

 

I recently removed the transmission and transfer case from my jeep to fix the clutch. I used a Harbor Freight "Low Lift Transmission Jack" to lower the combo and raise it back up when it was time for the installation. The jack was worth the 80 bucks (with 20% coupon).