Dana 20 oil pan

[73azbronco]

Big tires and driving in Low range for longer periods. I actually don't know how this was found out but guy's started going out and under to touch the box.
The oil was boiling inside. The oil capacity is not much in the D20.
The parts that did give where the Roller Bearings and Thrust Washers around the Intermediate Shaft.
The Intermediate Shaft was swapped for the axle I posted above. Ball bearings did replace the Roller bearings.

It's sounding like you're stressing the d20 way beyond design, and folks do that but that's why they go atlas.

 

[Qumanchew]

I don't know jack about baja, do they run in 4L a lot? I just assumed it was mostly high speed in 4H.

We used to do a lot of snowmobile riding in upstate NY and Canada. Somewhere, about the late eightys, early ninety my buddy buys a new Polaris. It had the engine coolers mounted under the running boards, everyone else's had the coolers up in the tunnel, above the track where they would constantly get snow thrown at them. We all thought this was the best idea since sliced bread. With the coolers directly below your feet it would keep them warm. Awesome, right? Not so much. If the conditions weren't right like hard packed snow the sled would overheat. If it got to be 35-40f he was screwed.

With the t case being tucked up in there I can see it not actually getting hit by a lot of snow. Interesting conversation for sure.

 

[Yeller]

The extended running in low range makes perfect sense. It is well known that guys that run a lot of sand eat up intermediate shafts. Reducing heat definitely helps, the bearing/shaft mods are the only real solution. I'm contemplating another build, using a D20, heat for its intended use is my concern, was already looking at this or building something similar. I know if I build this truck and it turns out like in my head..... it will see long runs in low range running 0-30mph and by long, 100+ miles per day in country you don't want a transfer case failure. Albeit 2 low would be most of the miles but the intermediate shaft is still spinning. I may suck it up and do an atlas but would rather try to use parts I have. My other trucks see similar use but have Atlas's in them.

 

[73azbronco]

I mean realistically, a D20 was designed to be engaged, get across a stream, and go back to 2hi. We are lucky it was way overbuilt for that purpose.

 

[Broncobowsher]

I mean realistically, a D20 was designed to be engaged, get across a stream, and go back to 2hi. We are lucky it was way overbuilt for that purpose.

I think it is more realistic that it was designed for a 60HP 4-cylinder. We are lucky it can take the V8 power as well as it does.

 

[Viperwolf1]

I don't know jack about baja, do they run in 4L a lot? I just assumed it was mostly high speed in 4H.

Not at all. Mostly 2wd with some 4 hi.

 

[73azbronco]

I think it is more realistic that it was designed for a 60HP 4-cylinder. We are lucky it can take the V8 power as well as it does.

Hmmmm, maybe 60hp inline 6 you mean? Not sure ford had 4 cylinder back then.

 

[Broncobowsher]

Hmmmm, maybe 60hp inline 6 you mean? Not sure ford had 4 cylinder back then.

I was thinking more of the original Jeep applications. Jeep was using a Dana 20 since '63

 

[73azbronco]

I was thinking more of the original Jeep applications. Jeep was using a Dana 20 since '63

ah, got me.

 

[Viperwolf1]

One other factor may be the weight of oil used. Down here where it's mild or even hot all the time, a heavier oil is typically used. Up near the arctic temps can get pretty low. I've seen -40 high temps when I was stationed in northern Greenland. It would be almost impossible to get parts moving at those temps with similar oil.

 

[Geiri]

One other factor may be the weight of oil used. Down here where it's mild or even hot all the time, a heavier oil is typically used. Up near the arctic temps can get pretty low. I've seen -40 high temps when I was stationed in northern Greenland. It would be almost impossible to get parts moving at those temps with similar oil.

Good point

 

[Geiri]

I mean realistically, a D20 was designed to be engaged, get across a stream, and go back to 2hi. We are lucky it was way overbuilt for that purpose.

I guess Ford did not anticipate 40"+ tires under the Bronco in heavy snow at the time

 

[Speedrdr]

I guess Ford did not anticipate 40"+ tires under the Bronco in heavy snow at the time

OR 3 1/2” lift and 37s to 44s in the Mississippi Delta mud.

Randy

 

[bronco italiano]

View attachment 912604 Now to clarify, I live in Iceland and we drive mostly in heavy snow.
So the Dana 20 heats up a lot. More oil would help with cooling and there are places in the D20 that don't take heat well.
Here in Iceland in the old days (before better transmissions and transfer cases), we did go as far as implementing an oil pump in the D20 to keep the parts in an oil bath all the time, as well as adding an oil cooler.

Some even built a new axle into it with O rings and bearings. Measurements are in MM. See attachment.
Such modifications are to much for me. But the extra oil would sure help.

Did you try Swepco 201 gear oil?

 

[Geiri]

Did you try Swepco 201 gear oil?

No I did not. I am searching it now

 

[bronco italiano]

Very high quality oil. All the old Porsche 356 racers use their gear and engine oils.

 

[Madgyver]

FWI, years ago there was a member here who made plastic (Lexan?) covers. Sort of a gimick, you could inspect your oil/gears through the plastic. Don't remember ever hearing of any issues with those either.

That was TOFIC.
The Old Fart In Canada

I wonder how he is doing. Last I remember his wife had passed.

 

[ntsqd]

One other factor may be the weight of oil used. Down here where it's mild or even hot all the time, a heavier oil is typically used. Up near the arctic temps can get pretty low. I've seen -40 high temps when I was stationed in northern Greenland. It would be almost impossible to get parts moving at those temps with similar oil.

A friend's dad was born in Iceland. He talked about building a small fire under the engine in his ex-G.I. GPW in the mornings to get it running. This was well before Icelanders started using geothermal to heat everything.

SWEPCO is very, very good oil. We used it extensively in Pro Sports 2000 racing. Not sure that it is best suited for this expected use, but for something like Yeller's project I'd be looking at it or a synthetic. Would be worth talking to SWEPCO to see if they have a specific recommendation for the OP's use.

 

[Geiri]

A friend's dad was born in Iceland. He talked about building a small fire under the engine in his ex-G.I. GPW in the mornings to get it running. This was well before Icelanders started using geothermal to heat everything.

Only 30 years ago we still did this on harsh winters. But time change and technology, Thank god