dana 20 transfer case

new to forum
i have a 75 cj5 w/ broken output shaft. my question rebuild or upgrade ?
i don't full blown off-road but i do screw around.

 

Rebuild!!!

 

You can buy several D20s complete for the price of anything better. I'd just replace the output with another stocker.

There is a stronger (and expensive) replacement for the output - if you are interested, read here: http://www.pirate4x4.com/tech/billavista/Uber-20/index.html

Welcome from Boston.

 

Great read on the adapter But it is longer than stock and in the cj5 length is a problem.
i already have a high angle drive line with 4 in. lift.
it seams like everything i'm reading says the d20 is a fairly good case, any other ideas over a rebuild

 

The Dana 20 rear output assembly can be replaced without disassembly of the transfer case. Problem is if the bearings are damaged the material will have found it's way into the rest of the transfer case and into the rest of the bearings. The other thing is if you do replace just the rear output assembly the speedo gears probably won't match so your speedo will be off and you won't know the condition of what you are installing. You could Remove the rear output assembly and rebuild it if you want to go cheap. Partsmike, R&P, Hermtheoverdriveguy, and others should have parts for this.

 

One other thing, if you actually broke your rear output shaft I'd double check your u-joint angles. If too steep you could be putting too much stress on the yoke and output shaft

 

I know i have high angle, hence the cv style drive line. would a traction bar help by keeping the rear end from rolling up?
the lift and tires have been on foor a couple of years, last weeks dry concrete burn-out is what did it.

 

I would definatly recomend some sort of traction bar if you continue to drive like that. Guilty my self of such. I made what i call a third link off the rear housing to just above the center,welded in a square tube between the frame rails just behind the t-case,Went to my local tractor supply picked up a adjustable top link used as my traction bar.Stoped my spring wrap,and is adjustable.

 

There you go.....

A traction aid can really help but this kind of abuse, anything can be broken.

 

the warranty wont cover abuse

 

My son found this weak link while jeeping in Moab this spring. Luckily a friend had a spare case to rob one from. But, exhausting searches all say it has been discontinued, "that's just silly", must be a conspiracy. Thanks for the Advance link, but a pricey conversion, about the price of a complete model 20 on ebay. Anybody have much luck finding just the shaft?

 

As I posted above, R&P, Partsmike, and others should have good used shafts and parts available. You will need to tell them if yours is fine or coarse spline (26 or 10 spline).

 

You were trying to find a Dana 20 output new? You should be able to find a complete transfer case locally - then rob what you need and give away or scrap the rest. Try the parts board on local Jeep web sites ...

http://www.colorado4x4.org/
http://www.cojeeps.net/
http://www.jeepz.com/forum/colorado-jeep-forum/
http://www.mhjc.org/
http://www.ontherocks4x4.com/joomla/

That's from maybe a minute of searching. The 20 is still plentiful AFAIK, and should not cost a lot. It's something of a cigar butt compared to the 300 or later cases.