D20 pops out of gear

[sbolejack]

Looking for some ideas as to what to look for that would cause my Dana20 to disengage the rear, when front & rear are engaged while off-road? Is there any adjustments that can be made?

 

[NC-Fordguy]

Looking for some ideas as to what to look for that would cause my Dana20 to disengage the rear, when front & rear are engaged while off-road? Is there any adjustments that can be made?

Typically this is a symptom of end-play out of spec at the rear output shaft. If that's ok look at detent springs. Lastly shift fork wear.

 

[jeff_gates]

Bungee cord.
I'm working on a pull rod contraption connected to the shifter rod and a locking pin.

 

[DirtDonk]

Any previous modifications done to the transfer case? How many miles on it? Been doing it long?
What about force? In other words, is it something that the bungee cord suggestion would fix, or is it impossible to keep in gear even when pushing on the shift lever?

paul

 

[BIGED]

Used the bunge cord for years it only jumped out on down hill when load released
A few years ago won some new springs and detent balls at Ocbr it fixed my problem should have bought them years before

 

[Viperwolf1]

Bungee cord or anything else that constantly forces the shift lever will cause excess wear between the shift fork and sliding gear. I would advise finding and fixing the problem.

 

[707Bronk]

Bungee cord or anything else that constantly forces the shift lever will cause excess wear between the shift fork and sliding gear. I would advise finding and fixing the problem.

X2 - forcing it to stay in place will only wear out other components that are harder to replace.

You could try detent springs, but even that may be masking the issue.

 

[sbolejack]

PO had it rebuilt and installed just prior to me purchasing with Terra Low gears and WH 300m rear output shaft. So it has under 100 miles on it.

 

[sbolejack]

Bungee cord or anything else that constantly forces the shift lever will cause excess wear between the shift fork and sliding gear. I would advise finding and fixing the problem.

Just sent you a PM.

 

[sbolejack]

Just PM'd you

 

[Buldozer]

Steve, my experience has been to keep this from happening with an off road rig running terra low gears: set up the D20 to ford end play specs, then remove a 10 thousands shim. It will run fine and no longer jump out of gear. If you do keep running it with it jumping out, the terra low gears tend to break eventually it seems. Best of luck buddy

 

[Viperwolf1]

Just sent you a PM.

I know the tcase is tight. You might give these a try. The stock springs and plugs are not very adjustable. http://shop.broncograveyard.com/Adjustable-Detent-Balls-and-Springs/productinfo/11674A/

Move the shifter between neutral and high range and tighten the screws down. Then back off about a turn and tighten the lock nut. That will give you good spring pressure without binding.

 

[sprdv1]

Good stuff, I have this same issue at times. Guess I need to get rid of the bungee cord, lol