Dana 20 Cluster gear removal/replace

[SHX669]

Seems I remember that I can't replace the cluster gear without totally removing the TC and tearing into it. I'm going to remove the rear output housing assembly and thought while I was at it replace the cluster gear if possible .
So is it possible with the right technique or do those 50 loose bearings make it impossible ? -- And no -- I don't want to "drop" the TC

 

[sanndmann3]

Back when I had a Dana 20, it would chew up thrust washers on a regular basis. Low range and 5-6K rpm probaby had something to do with it... anyway, I was able to get the cluster gear out with the T case still in the vehicle so I could swap out washer. The hard part is getting the shaft out. Not much room in front to swing a hammer to push the shaft. Ended up using a crow bar and different sockets to pry/lever it out (hope that makes sense).
Good luck and use vasolene on all those little roller bearings when you put it back together...

 

[Chief Master Sergeant]

Having just finished reassembling my transfer case, I think you would have one hell of time getting it back in while in the vehicle.

 

[langester]

I just did mine a couple nights ago. I had the t case on the bench though. I think you could do it, however it might not be very fun. The hardest part to me was getting those bearings and spacers to stick to the dowel I was using long enough to get it in the gear. I put vaseline in the freezer over night and it made it go a lot easier. Once that was in place I glued the thrust washers to the case with the frozen vaseline. I used another piece of dowel in the front hole pushed in flush with the thrust washer to hold it in place. I used the shaft on the back side the same way, just far enough in to hold the thrust washer. I got the gear in place and drove the pin in. It was easier than I thought it would be. Worse case is you get tired of messing with it and drop the t case to finish.

Good luck!