Dana 20, Idler Shaft, Shift Pill, and round gasket questions.

[rockingm82]

Dana 20 rebuild is a trying test for this new shade tree mechanic.

I have several questions.

1. The idler shaft: I read a rebuild post on the Dana 20 where the author mentioned an o-ring on the idler shaft. I don't recall one coming off during the dismantling operation and I didn't receive one in the rebuild kit. Is their actually a required o-ring for the idler shaft?

2. The Dana 20 is missing a shift pill. It had the shift pill installed in the sleeve that doesn't run completely through the case, but the shift pill is missing from the other sleeve (this is the sleeve you can see through if the rails are removed). Would there be a reason for a PO to remove this pill. Where the heck can I find a new one to replace it?

3. I received a round gasket in the rebuild kit and I have no idea where this goes. See picture one.

4. I'm a noob so forgive on this one, but there is one washer with two flanges on the inside that I'm not sure where it came from, nor can I find it in any manuals. See picture two.

Thanks for the help guys. This is my first attempt at a major project and I'm completely on my own outside of this website.

 

[Izzy]

Is this Dana 20 rebuild month? I'm doing mine as well and a few others are two so lots of posts about Dana 20s this week.

1. There is a o ring for the idler shaft. There should be an idention close to the top where the set plate keeps it in place. I can take a pic later but I bet someone will have one here before I get home.

2. T shift or J shift? T has 2 and J has one.

3. Ignore this one

4. I never saw one like that on my kit or in my dana 20. you sure it came from the dana 20 or was it in the rebuild kit?

 

[turbotim2]

My kit also had a random seal like yours, put it in your spare parts bin. I also don't recall seeing the ring in pic 2 either. The J-shift has one ball on each side like Izzy said.

 

[rockingm82]

Thanks for the replies and I have a few answers for my questions!

1. According to Tom's, they do not ship an o-ring for the idler shaft. It is not needed and did not come on early model Broncos.

2. It's a T shift so I have no idea why it's missing a pill interlock. I have one on order from Tom's.

3. Will ignore it.

4. Perhaps this is from the transfer case to 3 speed adapter. I have the original and the new one, but I don't remember where it came from.

Thanks for the help!

 

[Viperwolf1]

Thanks for the replies and I have a few answers for my questions!

1. According to TBG, they do not ship an o-ring for the idler shaft. It is not needed and did not come on early model Broncos.

2. It's a T shift so I have no idea why it's missing a pill interlock. I have one on order from TBG.

3. Will ignore it.

4. Perhaps this is from the transfer case to 3 speed adapter. I have the original and the new one, but I don't remember where it came from.

Thanks for the help!

Go to a harware store and find an o-ring that fits tight in the groove and sticks up just a little. When you drive the shaft in it'll cut the top off the ring and seal the shaft from leaking. Put some sealant on the front side hole before you drive the shaft through it.

T shift uses both pills unless it's been modified for use with a twinstick shifter.

Toss the round gasket.

The round tanged washer is used on the front output shaft of a T shift next to the snap ring.