Dana 20 idler gear very tight

[Green_Bastard]

Hey guys, I'm in the process of rebuilding my Dana 20 and I found that after the idler gear/shaft is install, things are so tight that its difficult to move. To validate that nothing else is causing it, I've removed the front and rear drives leaving just the idler gear/shaft and its so tight I can hardly turn it. I've installed new bearings and thrust washers as part of the rebuild. Any ideas on what would cause it to be this tight?

 

[Viperwolf1]

Hey guys, I'm in the process of rebuilding my Dana 20 and I found that after the idler gear/shaft is install, things are so tight that its difficult to move. To validate that nothing else is causing it, I've removed the front and rear drives leaving just the idler gear/shaft and its so tight I can hardly turn it. I've installed new bearings and thrust washers as part of the rebuild. Any ideas on what would cause it to be this tight?

New thrust washers? If so where did they come from?

I put one together recently that was too tight. New thrust washers were just a few thousandths too thick. I ended up using one new and one old washer.

 

[Boss Hugg]

or use a file to clearance the washer just a bit?

 

[Green_Bastard]

New thrust washers? If so where did they come from?

I put one together recently that was too tight. New thrust washers were just a few thousandths too thick. I ended up using one new and one old washer.

I got this kit from WH. Interestingly it came with two sets of thrust washers. I've been messing with it since posting this and I found that when I loosen the idler shaft lock plate, it frees it up a bit. The locking plate was bent a little and pressed inward on the shaft. I straightened it out and it seems a little better now. I can turn the gears using the flange but how do I know if its loose enough or still to tight?

 

[Green_Bastard]

Bump


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[Viperwolf1]

I got this kit from WH. Interestingly it came with two sets of thrust washers. I've been messing with it since posting this and I found that when I loosen the idler shaft lock plate, it frees it up a bit. The locking plate was bent a little and pressed inward on the shaft. I straightened it out and it seems a little better now. I can turn the gears using the flange but how do I know if its loose enough or still to tight?

When you press or knock the shaft in it can temporarily deform the case slightly. That sounds like what may have happened. Try giving it a couple blows on the front of the case near the shaft to relieve the tension.

If you can spin the gears from the yoke by hand (no tools) it's good.

 

[Green_Bastard]

When you press or knock the shaft in it can temporarily deform the case slightly. That sounds like what may have happened. Try giving it a couple blows on the front of the case near the shaft to relieve the tension.



If you can spin the gears from the yoke by hand (no tools) it's good.

Hey Viper, that did the trick and I can turn it by hand.

Thanks once again for your help!!!


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