Dana 20 idler cluster "end play"

[Bickster]

Just finished my rebuild. Used the WH Deluxe kit. My question is how much does the gear cluster move forward and rearward? I used new thrust washers and the 3 spacers that hold the new needle bearings. Just concerned how much the cluster walks on the shaft. I could darn near put another thrust washer in! Thanks!

Bob

 

[broncodriver99]

There should be practically no end play. All of the ones I have done have been pretty snug. Did you relieve the tension on the case by pounding it with a dead blow around the idler shaft on each side? Are you sure both thrust washers are still in there? They like to fall out.

 

[Bickster]

Aw firetruck! I know better than this. Thanks 99. Sure enough the rear thrust is laying in the bottom of the case. I was convinced it was in place. Thanks again.

Bob

 

[Viperwolf1]

Before you set the gear in place put the shaft in just enough to hold the rear thrust washer up. You can use a similar object to do the same for the front thrust washer.

 

[Bickster]

I think my dowel got a little ahead of the shaft. As the dowel emerged it had the thrust washer captured so I never even checked it. Dumbass. Then the space almost exactly the width of a washer. It was 11:00 so my brain was trashed.

Now I have too much preload on the rear output shaft. Torque the yoke down and it won't spin. I've got every shim I have on the thing but no dice. I'm learning a lot the hard way as usual!

 

[Bickster]

So I thought I would just pony up for the heavy duty output shaft. That was before I priced it out. Whoa!

 

[Viperwolf1]

Now I have too much preload on the rear output shaft. Torque the yoke down and it won't spin. I've got every shim I have on the thing but no dice. I'm learning a lot the hard way as usual!

You need to reuse some of the old shims. 0.080" of shim thickness is a good starting point. Original shims have a couple thick ones (0.030") and some thin ones. Usually the thin ones break up over time. Rebuild kits only include the thin ones.

 

[Bickster]

Yep! and I have the old ones plus all the new ones. I obviously cocked something up!

 

[Viperwolf1]

Make sure the cups are pressed all the way in.

 

[Bickster]

Beat on it some more? No problem lol. I think I put the speedo gear in backwards so it needs to come apart anyway. I will be able to do this in my sleep by the time i'm done.

 

[Viperwolf1]

Beat on it some more? No problem lol. I think I put the speedo gear in backwards so it needs to come apart anyway. I will be able to do this in my sleep by the time i'm done.

Look at the backside of the cup to see if there's a gap between it and the ledge it sits on. Those are kind of weak and you can break them with a lot of pressure.

Speedo gear should work either way. Sometimes the plastic ones get pushed off center.