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D20 and 3 speed rebuild tips

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Joe473

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Joined
Jul 16, 2012
Messages
954
Finished T case yesterday afternoon. Feels good. Did the JBG adjustable detent and zf adapter also. Thanks for all the help on here.

Wood dowel, with vaseline and a couple of tie wraps made easy work of Idler gear assembly.

Vaseline also worked great on input pilot.

Not a fan of newer style seals in rebuild kits but with the zf adapter the input seal appears to go away anyway

Thanks again.

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.94 OR

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Bronco Guru
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Jul 5, 2009
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boy I wish someone would do a vid on a rebuild.

That might take the mystery out of it.

I did mine a couple years ago and used a double heim rod in place of the shifter to T-case connector. Tighter and allowed for some adjustment of the shifter front to rear on my T- shifter as I don't have a factory detent setup.
 
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Joe473

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Jul 16, 2012
Messages
954
Ok so I appear to have messed up the rear output preload....

I have steel speedo gear on output shaft and it works intermittently. If I accelerate hard it starts working which leads to believe too much preload and not enough shims to squeeze the speedo gear.

Along with that it did pop out of gear after very hard acceleration to 75 and then quick engine braking decel.

Needless to say I ordered gaskets and seals from Wildhorse and will update thread. When I disassemble My gut tells me preload should be closer to 5 inch #'s and I may have a slightly worn shift fork.

Also I think viper wolf or someone mentioned setting it to .003 or lower measurable endplay with setup bearing and then removing a couple of thousandth of shims for final assembly to get right at 000 endplay without overdoing it.



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Joe473

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Jul 16, 2012
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954
Good news endplay and speedo gear were good. Pulled the output assembly and rechecked everything and it's tight .000 endplay and about 10 inch #'s of torque with seal.

Bad news it did pop out of gear once so far after reassembly. Speedo issue appear to be in new head.

I measured clearance on forks and only .018 on rear and about .020 on front.

After doing a little more research I'm going to crank down on the rear detent a little more. Hopefully this helps.

Anyone ever see advance adapter d20 input bearing cause this issue? Or Is it possible the rollers on the input pilot get worn and cause this?

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Viperwolf1

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electron whisperer
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Aug 23, 2007
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24,344
Good news endplay and speedo gear were good. Pulled the output assembly and rechecked everything and it's tight .000 endplay and about 10 inch #'s of torque with seal.

Bad news it did pop out of gear once so far after reassembly. Speedo issue appear to be in new head.

I measured clearance on forks and only .018 on rear and about .020 on front.

After doing a little more research I'm going to crank down on the rear detent a little more. Hopefully this helps.

Anyone ever see advance adapter d20 input bearing cause this issue? Or Is it possible the rollers on the input pilot get worn and cause this?

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When adjusting those detents I like to put the shift rail between gear positions (between neutral and high on T rails). Crank the detent down until the spring fully compresses, then back off 1/2 turn and tighten nut. That should give you just enough travel and maximum spring compression to hold it in gear.
 
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Joe473

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Joined
Jul 16, 2012
Messages
954
Thank you, I'll try it that way. I did it by feel and probably a little too loose.

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Joe473

Sr. Member
Joined
Jul 16, 2012
Messages
954
When adjusting those detents I like to put the shift rail between gear positions (between neutral and high on T rails). Crank the detent down until the spring fully compresses, then back off 1/2 turn and tighten nut. That should give you just enough travel and maximum spring compression to hold it in gear.
Thanks for that advice. I was 3 or 4 full turns from that. Just adjusted it and took it for a 10 mile 75 mph highway test with no issues. Hopefully that's my last tweak to getting this back to full weekend road trips!!

For anyone doing this in the truck. Use 11/16 swivel socket over passenger side top of case. Def need the 1" body lift and 1 hand holding socket on locknut when u loosen/tighten. 7/32 Allen for JBG adjustable detent.

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Viperwolf1

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electron whisperer
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Aug 23, 2007
Messages
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That 1" body lift really helps access to things like this.
 
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