Dana 20 idler gear

[Fastwest]

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]

Are you doing this with the transfer case horizontal or vertical?
Gravity fights you if horizontal, but not vertical.

 

[Fastwest]

Looking straight down into the inspection cover

 

[Viperwolf1]

Are the thrust washers new or old? My experience is that new ones are made too thick.

 

[Fastwest]

They are new. Maybe try the old ones from the T-shift? The J-shift ones were scored so I tossed them

 

[Fastwest]

So I measured the new ones...they are .098, old ones .093.

 

[Fastwest]

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.

 

[Fastwest]

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]

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!

 

[Fastwest]

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]

The vendors I have spoken to, do know. I did not include their names since I was callin'-out Crown Automotive.