Dana 20 Output Shaft Assembly Rebuild Without Removing T-Case from Rig - You Tube Video

[OldBlue76]

Hi gang,

I recently rebuilt the Dana 20 output shaft assembly on my 76, new bearings, races, seal and yoke nut. I have rebuilt a few Dana 20s over the years but always with the T-case removed. I didn't want to remove the transfer case as it only needed new output bearings, so I did it with the T-case in the rig. I made a You Tube video of it to share with the group. It may be a bit remedial for most of you, but some folks might find it useful. One thing I found that was a bit surprising was that the thin shim in the shim pack was disintegrating from rattling around in there with the loose bearings I guess. It can be seen about 4-1/2 minutes into the video.

 

[raleigh_bronco]

Nice instruction. Thanks for sharing.

You mentioned the pinion nut takes a 1 1/8“ socket, but for some reason I thought the nut is 7/8-14 which requires a 1 5/16” socket? I could be wrong!

 

[cldonley]

Thanks for the video! Getting ready to do some work on the D20, so a big help for me!

 

[LoneRanger]

Bump for a good video. It's amazing how fast you forget things when you don't do this all the time.

L.R.

 

[Madgyver]

I recently did this. kinda like muscle memory. didn't bother with a gasket but hunting for one is a chore. RTV it is.

 

[73azbronco]

perfect opportunity for gasket material of your choice, small ball peen hammer and tab your way to a new gasket. With RTV.

 

[Yeller]

Nice instruction. Thanks for sharing.

You mentioned the pinion nut takes a 1 1/8“ socket, but for some reason I thought the nut is 7/8-14 which requires a 1 5/16” socket? I could be wrong!

Typically that is correct. That is a typical thread size for output shafts. They make a reduced hex size nut that is 1-1/8” for those applications. Some yokes will not accept the larger diameter nut and allow a socket to fit or you have to have a special machined thin wall socket to remove/install the nut. 1-1/8” is pretty standard for that application

 

[Madgyver]

perfect opportunity for gasket material of your choice, small ball peen hammer and tab your way to a new gasket. With RTV.

I ran out of RTV. Permatex #2 it is..
container of roller bearings flipped into the air on my work cart. Of the 13 rollers, I found 12. stole 1 roller from other output unit to complete install.