Dana 20 cluster gear shaft

[savage]

I am just finishing up my rebuild on my Dana 20.I just received the shaft.My question is I noticed the new shaft is a little snug and the slot for the new o-ring is skinner than my old one. I had to go to hardware store and get a thinner one. I went ahead and put it in till their was a 1/4in left I used silicone and put it the rest of the way. I notice that since it is so snug it ends up shaving the o-ring anyway. Has this happen to any one else?

 

[70_Steve]

I notice that since it is so snug it ends up shaving the o-ring anyway. Has this happen to any one else?

I think it happens to everyone. That's why I put silicon on both ends.

 

[addicted]

Yea. My O ring got shaved on the install too.

 

[bad 68]

Yes, I could'nt get the o ring to shave. Just would not go. I ended up leaving the O ring out and using my favorite gasket maker: Yamabond # 4.

 

[Viperwolf1]

If I don't get a clean, thin cut on the o-ring I pop it back out and try another. When you get the groove 1/2 way in use a small screwdriver to push the o-ring in under the case lip.

 

[savage]

Has any one tried Permatex® Automatic Transmission RTV Sealant to mate the transfer case adaptor to both trans and tranfer ?