Dana 20 stuck in 4L

Replaced the gaskets on my Dana 20 and cleaned everything inside. When I re-assembled the insides, the shift rods were in 4L. Now that I finished everything up, the shift rods seem to be stuck in 4L. Any suggestions? Do I have my linkage installed correctly?





I also ordered a Novak twin stick kit that should be here next week but it might not be worth installing yet until I can make sure nothing is jammed internally

 

I think I figured out the problem. I never removed the detent spring and ball for the shift rods prior to disassembly. Any suggestions on how to remove them with the rods in the 4L position?

 

On a Dana 20 the shift rails have to be removed to get to the detent springs and balls. They are under the shift rails.


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then how do I get the rods out of 4L?

 

If you replaced the gaskets how did you remove the front housing without removing the shift rails?


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I didnt fully remove it, just pulled it away. I couldnt get the shift rails out

 

Sounds like debris got in the shift rail passages jamming them up or you jammed the shift rails in the interlocks. Might take the linkage loose and gently tap on the shift rails one at a time to see if you can get them to move. The transfer case must be disassembled to get the shift rails out.

 

Figured out the problem. It was the linkage, installed a twin stick conversion today and it works perfect