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Dana 20 idler gear

Fastwest

Sr. Member
Joined
Feb 7, 2015
Messages
371
Team,

I’m trying to get this Dana 20 rebuild finished up! Im having tons of trouble getting the idler gear in without one of the bushings sliding out of place. Im using some super tacky transmission gel to hold everything in place, but just can’t get it. I’m also using the shaft on one end and a 7/8 socket on the other. I get sooooo close. Is this just a 2 man job or what? I am installing gears from a T-shift in my J-shift, but heard they fit right in. Any help would be appreciated

FW
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,632
Are you doing this with the transfer case horizontal or vertical?
Gravity fights you if horizontal, but not vertical.
 

Viperwolf1

Contributor
electron whisperer
Joined
Aug 23, 2007
Messages
24,344
Are the thrust washers new or old? My experience is that new ones are made too thick.
 
OP
OP
F

Fastwest

Sr. Member
Joined
Feb 7, 2015
Messages
371
They are new. Maybe try the old ones from the T-shift? The J-shift ones were scored so I tossed them
 
OP
OP
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Fastwest

Sr. Member
Joined
Feb 7, 2015
Messages
371
Good call Viper! Can’t belief I didn’t measure before posting. I guess I just had too much faith in the new parts. Looks like the idler shaft seal isn’t going to work as well. Original had a square profile, new is too fat and round. Sucks that the new parts won’t fit...going to try again now.
 
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Fastwest

Sr. Member
Joined
Feb 7, 2015
Messages
371
Awesome! So got it in! How can vendors sell stuff like this? If I didn’t have and extra tcase to rob parts from I would be screwed. Or do guys manage to get them in? Thanks for the help guys...I’m sure I’ll have more questions before it’s all said and done
 

JB Fab

Sponsor/Vendor
Bronco Guru
Joined
Mar 21, 2004
Messages
1,315
We have disconnected selling the kits due to the issues.
My understanding is that all of the thrust washers in everyone's kits are coming from Crown. The company we get our kits from has been putting pressure on Crown to them to get it fixed, but Crown does not seem to be very motivated.
I have also found several of the washers/spacers used to separate the idler needle bearings to be non-conforming, and suspect them in the failure of at least one rebuild that a friend did.
If you can find a kit that is over 18 months old you might be ok.

Use of the non-conforming parts causes damage to the case itself if thrust washer spins, or the needle bearings seize and spin the idler shaft.

It really pisses me off that we are unwittingly destroying our irreplaceable classic rigs with cheap-ass Chinese crap!
 
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Fastwest

Sr. Member
Joined
Feb 7, 2015
Messages
371
Good post JB. If I was aware of the issue before purchase I would have asked them not to include those parts. I wonder if all the vendors know? They should at least give a heads up to the customer. What a headache.
 

JB Fab

Sponsor/Vendor
Bronco Guru
Joined
Mar 21, 2004
Messages
1,315
The vendors I have spoken to, do know. I did not include their names since I was callin'-out Crown Automotive.
 
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