rebuilding d20 transfer case

bigbadktm · Jun 1, 2009

I have the rebuild kit for it but not the know how. I was wondering if anybody close to san diego has rebuilt their own and wouldnt mind doing another, or is there a place that you would recommend taking it to. What price range should I be looking at?

I called one place but they wanted me to bring it in to give me a quote. I tore it apart for routine preventative maintenance, worked fine. I almost regret tearing into it, but thought some new bearings would be nice before buttoning it up to the tranny.

Viperwolf1 · Jun 1, 2009

Every Bronco owner should rebuild at least one D20. They're really pretty easy. I think JBG has a link to the repair manual.

Oatmeal · Jun 1, 2009

One place that comes to mind is Border Parts in Spring Valley (not too far from San Diego). I bought my rebuild kit from them several years ago (I think they're still around) and if I remember correctly, they work on them as well. ------------Hans

Oatmeal · Jun 1, 2009

Here's some info I was able to find (no website): http://www.insiderpages.com/b/15237532144 -----------Hans

TOFIC · Jun 1, 2009

don't pay money when you don't have to!!! DIY!!!
Not hard, get the ford manual and have at it. Afternoon job
go for it!!
TOFIC

Chief Master Sergeant · Jun 1, 2009

I'm with you dude. Scares the hell out of me. I think I'm going to replace the seals and gaskets only. Maybe I'll find a spare one somewhere and try on it.

rjlougee · Jun 1, 2009

Viperwolf1 said:
Every Bronco owner should rebuild at least one D20. They're really pretty easy.

I agree, everyone should rebuild one; however, I will also state that the only people I've ever heard say that are the folks who've never pulled the intermediary shaft out and replaced all the bearings inside.

Most folks pull that out out and want to just go buy another one, rather than figure out how to get it back together.

I just did one, including a Tera-low 3.15 kit install, big PIA.
Joe

sprdv1 · Jun 2, 2009

bigbadktm said:
I have the rebuild kit for it but not the know how. I was wondering if anybody close to san diego has rebuilt their own and wouldnt mind doing another, or is there a place that you would recommend taking it to. What price range should I be looking at?

I called one place but they wanted me to bring it in to give me a quote. I tore it apart for routine preventative maintenance, worked fine. I almost regret tearing into it, but thought some new bearings would be nice before buttoning it up to the tranny.

Which rebuild kit did you get..?

70_Steve · Jun 2, 2009

It's not that hard... really!!! Here's a a link to a Dana 20 service manual. This is all I used when I rebuilt mine. Yes, there's a couple bearings that are easier removed and replaced with a press, which I don't have. So, I took the shafts and bearings to a local shop, and for $20 had them done.

There are a few tips and tricks to getting the job done easier, but it really is straight forward.

http://www.classicbroncos.com/dana20/dana_20_manual.htm

KyleQ · Jun 2, 2009

The pictures are not showing up in that link... is it the link or the work computer?

70_Steve · Jun 2, 2009

KyleQ said:
The pictures are not showing up in that link... is it the link or the work computer?

Maybe the work computer. They show up on mine at work. And usually I can't get access to anything at work.

TN1776 · Jun 2, 2009

rjlougee said:
I agree, everyone should rebuild one; however, I will also state that the only people I've ever heard say that are the folks who've never pulled the intermediary shaft out and replaced all the bearings inside.

I pulled mine completely apart and replaced every single bearing and seal. It is not that difficult. Just take your time and its really not that bad. Took me about a day in the garage, working slowly with a buddy's borrowed press and help from my father.

I would do it again, it was pretty darn easy.

Viperwolf1 · Jun 2, 2009

rjlougee said:
I agree, everyone should rebuild one; however, I will also state that the only people I've ever heard say that are the folks who've never pulled the intermediary shaft out and replaced all the bearings inside.

When I go to the trouble of pulling something like a trans or D20 out you can bet that I'm going through every bit of it before it goes back in. Those R&R jobs are just too much work to have to do over.

rjlougee · Jun 2, 2009

So what trick did you guys use to hold all the needle bearings in the intermediary gear while you pounded the shaft back in?
Joe

70_Steve · Jun 2, 2009

rjlougee said:
So what trick did you guys use to hold all the needle bearings in the intermediary gear while you pounded the shaft back in?
Joe

I cut a wooden dowel, the same diameter as the intermediate shaft, and same length as the ID of the case. Put all the needle bearings in place, slid the dowel through the middle, put the thrust washers in place on each end of the dowel, and "dropped" into place. Then just used the intermediate shaft to tap the dowel out the other side.

I've heard some guys will use a piece of PVC pipe, instead of the wooden dowel.

Viperwolf1 · Jun 2, 2009

70_Steve said:
I cut a wooden dowel, the same diameter as the intermediate shaft, and same length as the ID of the case. Put all the needle bearings in place, slid the dowel through the middle, put the thrust washers in place on each end of the dowel, and "dropped" into place. Then just used the intermediate shaft to tap the dowel out the other side.

I do the same. Use lots of grease to hold the rollers together. I keep the dowel with my spare t/c parts.

bigbadktm · Jun 2, 2009

i bought the full kit with bearings from toms. i just dont have a press and no longer have the time/place to rebuild it on my own. Moved, so i dont have my workspace anymore, and the bronco stays at the parents house 45min away. I may call border parts adn find out, they're still there off of bancroft exit in spring valley.

Viperwolf1 · Jun 2, 2009

You can do it without a press if you have a big brass hammer. Use the sliding gears as a base to knock some of the old bearings off. I also like to freeze the input/output shafts and heat the new bearings in the oven. They slide right on. For setting the rear output endplay (.003-.005") I use a BR15118 as a setup bearing so there's no fighting to get the shaft apart when changing shims. Makes the job quick and easy.

bigbadktm · Jun 3, 2009

well looks like I am gonna pony up and just drop it off at border parts and call it a day. Not too far outta my way, and should be right around $200. Cheaper than my steering at least. Then I can slap the tranny to the motor and d20 to the tranny and drop that mutha in. One step closer to being able to power itself around again, can't wait.

The other problem I have is that I took it apart a few months ago and even with pics probably couldn't remember where everything went. It also needs some new bolts for the inspection cover as the PO used about every available loose bolt to hold it on there, washers galore.

localrich · Jun 3, 2009

I'd be willing to help you out after BBBB but i'm in Garden Grove. It's not that hard if you take your time. I have a dinky HF press that works great for this and trans rebuilds.

I helped Rick with his 4spd rebuild and it took a few times because he disassembled it and forgot the location of a snap ring or 2 lol

rebuilding d20 transfer case

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