dana 20 refresher

the Last time I removed my dana 20 transfer case from my jeep it got hung up and wouldn't come free from the transmission. with a lot of prying and cussing it finally popped free. The time before I seem to remember putting the transfer case in a certain gear and it came out easy. Does anyone remember if that is true?

 

Found this online:

1. Raise the vehicle on a hoist.
2. Support the transfer case shield with a jack and remove the bolts
that attach the shield to the frame side rails. Remove the shield.
3. Drain the transmission and transfer case lubricant.
4. Disconnect the front and rear drive shafts at the transfer case (Fig.
2).
5. Disconnect the speedometer cable at the transfer case.
6. Disconnect the shift rods from the transmission shift levers. Then,
place the first-reverse gearshift lever into the first gear position, and
insert the fabricated tool (Fig. 2). This tool will prevent the input shaft
roller bearings from dropping into the transmission case when
separating the transfer case from the transmission and output shaft.
7. Cut the lock wire and remove the two bolts, washers, plates, and
insulators that secure the crossmember to the transfer case adapter.
8. Remove the crossmember-to-frame side support attaching bolts.
9. Raise the transmission and remove the upper insulators from the
crossmember. Remove the crossmember.
10. Disconnect the shift rod from the transfer case shift lever bracket.
11. Remove the bolt that attaches the shift lever bracket to the
transfer case adapter, and allow the assembly to hang by the shift
lever.
12. Secure the transfer case to a transmission jack, and remove the
transfer case-to-transmission attaching bolts.
13. Move the transfer case and jack rearward until it clears the
transmission output shaft (Fig. 2). Lower the transfer case.

I found this at:

http://www.jbfab.net/Dana 20 4-Wheel Drive Transfer Case Manual.pdf

Hope it helps!!

 

Here's another one I found at:

http://www.offroaders.com/info/tech-corner/project-cj7/Teralow-Dana20-project-cj7.htm

...this one was actually a CJ Dana 20 and not an Early Bronco.

Removed the Dana 20

1. All 4 of the Jeeps tires were chocked very well so there was not possibility of it drifting. Also the Transfer case lub was drained.

2. As I said, I had the transfer case out already but in the process of doing so I had removed the gear shift cover plate in the transmission hump, the shift lever assembly.

I found a nice way to support the transmission while the drive train skid plate was removed. Using a piece of 1/4 inch angle iron across two floor jacks it supported the T-18 transmission directly so I could remove the Dana 20. During the process when it wasn't in the way I kept a floor jack under the transmission mount just in case. Redundant support is a good idea for safety reasons.

3. I removed the drive shafts.

4. I disconnected the speedometer cable at transfer case.

5. I removed transfer-case-to-transmission attaching bolts and muscled the transfer case out and onto the floor. It's a good idea to have eye protection on while under a vehicles, especially my Jeep with all the mud and crud that falls out when I'm working on it.

6. While I was down there, I remove transmission-to-transfer case gasket. I had also discovered that the transfer case to transmission adapter was loose, thus the cause of the noise. When I tighten it up again, I'll clean the bolts and treat it to some Locktite so they don't back out again.


With the transfer case on the bench it was time to break it down.

 

You shouldn't need to have it any specific gear to remove or install it as long as you have everything lined up properly. However, having the trans and transfer in gear can make it easier to install and line up the gear because everything isn't trying to turn out of register as you're installing. It does help line up the gear teeth a little easier in other words, but is not necessary. The input gear just fits through the transfer case hole so if you have it angled at all the gear wants to catch on the case.

 

thank you for the replies.... it came out without any problems....left it in gear...transmission in first and transfer case in nuetral. thanks a lot all !