Dana 20 main drive gear

[36Fan]

Gear has some rounding on the teeth but no visible cracks. The rear output sliding gear looks about the same.

Run it or replace it?

 

[Fastwest]

I replaced mine in similar condition. I had a few extra tcases laying around. Put T gears in my J shift for a slight reduction.

 

[cs_88]

If you do decide to replace it Tom's sells new ones.

https://www.tomsbroncoparts.com/product/dana-20-transfer-case-adapter-gear

 

[Broncobowsher]

I thought they are suppose to be a little rounded to help in engagement. Looks like they have some wear but only on the tips where the engagement happens. While not perfect I think it would be functional. Were you having any issues before the rebuild that would lead to thinking it was functionally bad?

Would I reuse it? If the rebuild was just to freshen up the case and fix leaks, it worked before the rebuild, yes I would use it. But if I was fighting an issue of popping out of 2WD, that would be on my short list of parts to replace.

 

[36Fan]

It never popped out of gear but I also never ran it in 4wd. It did make some noise, possibly from the yoke having so much play?

 

[Broncobowsher]

I don't see that dog clutch being the source of noise.
That dog clutch is rear output in high range. If there was a funny wear that would cause a jump out of gear it would be in 2WD and not 4WD. That is because the interlock pills will lock the rear output in place while the front is engaged (you can't nave the rear in neutral with the front in gear, in stock trim).

Little reminder since it shows up a time or two a year. Those teeth go into the transfer case when you put it together. The gear will go onto the shaft either way. Put it so the teeth face forward (toward transmission) and everything will fit fine. But you will have no rear output in high range (2WD or 4WD), and front output and all of low range will work perfect.

I would still be inclined to reuse the gear.

When you are done, there will be noise in low range. That is a given. Those gears are straight cut. Straight cut gears are noisy, no way around it. But that is only low range and it isn't real bad.

 

[66BlueGoose]

Has some wear, but nothing there would concern me.

 

[Viperwolf1]

The face of those dog teeth is not so important. The sides are where the power is transferred. If those are worn and tapered it's time to replace it.