Dana 20 rebuild progress pic

[skrit]

Thought I'd share a peek at my Dana 20 rebuild. I'll post more on my build thread. Wish the case tag wasn't so faded.

 

[rcmbronc]

Looks great. Is it bare CI or painted? If coated with what?

 

[Mikes79Bronco]

Looks really good, I need to yank mine out and do the same its leaking from multiple places.

 

[skrit]

Looks great. Is it bare CI or painted? If coated with what?

Scrubbed it with mineral spirits and a brass brush, coated with Rust Reformer, then engine primer and finally Cast Blast rattle can paint in cast iron color. Decided to do new goldish colored anodized grade 8 bolts I got from O'Reily's.

 

[Okie69]

Looks great. Digging the grade 8 bling.

 

[ford man]

Looks good

 

[Soylent]

Were you having any issues before the rebuild? What rebuild kit did you use? The full monty from WH?

 

[skrit]

Were you having any issues before the rebuild? What rebuild kit did you use? The full monty from WH?

I was not having issues back 10 years ago when my Bronco was actually assembled other than leaks which seems to be very common I'm doing a complete frame off so I figured, might as well rebuild it.
It's a fairly easy rebuild. No gears were worn or damaged so basically it was a tear-down, clean, re-bearing, re-gasket/seal and paint operation.

I bought these tools for the job from HF:
https://www.harborfreight.com/bearing-race-and-seal-driver-set-10-piece-63261.html
https://www.harborfreight.com/bearing-separator-and-puller-set-62593.html

I heated most of the bearings in an oven at 325 degrees for 15 minutes and they pretty much fell into place. Others, I used a MAP torch to heat up. I used the cheap transmission clutch press I bought from Amazon for the 4R70W rebuild to press the bearings on the rest of the way. For one of the bearings, I used a 1-1/4" cast iron pipe coupling and nipple to help press it on.

I got the rebuild kit from here: https://transpartswarehouse.com/bk2...nsfer-case-rebuild-kit-1966-1972-dana-20.html

After finding some scoring and excessive wear on the intermediate shaft, I ordered a "hardened" one from here: https://thejeepsterman.com/products...nsfer-case-1947-1986-willys-and-jeep-vehicles. It has not arrived yet so I hope it works for the Ford Dana 20.

I also ordered adjustable shift rail detents from JB fab.

 

[chrlsful]

I usta like the "Low D 20” K Bar S usta sell. Justa lower 1s gear to stuff in the housing, simple/cheep. Forged by TerraFlex’n called
the terraflow I think WH was the last to sell them. May B .5 a lower x-fer case (3 even steda 2.46 I think). The heep model will not fit in our case or sumpin. (Woulda liked 4:!! x 3 x 15 better than 4:11x2.46x15 inch, a 50 v 80 final drive, perfect 4 me/my conditions ~ 5 MPH in 1st& low - I seek an 60 to 80:1 ratio).

 

[Soylent]

I was not having issues back 10 years ago when my Bronco was actually assembled other than leaks which seems to be very common I'm doing a complete frame off so I figured, might as well rebuild it.
It's a fairly easy rebuild. No gears were worn or damaged so basically it was a tear-down, clean, re-bearing, re-gasket/seal and paint operation.

I bought these tools for the job from HF:
https://www.harborfreight.com/bearing-race-and-seal-driver-set-10-piece-63261.html
https://www.harborfreight.com/bearing-separator-and-puller-set-62593.html

I heated most of the bearings in an oven at 325 degrees for 15 minutes and they pretty much fell into place. Others, I used a MAP torch to heat up. I used the cheap transmission clutch press I bought from Amazon for the 4R70W rebuild to press the bearings on the rest of the way. For one of the bearings, I used a 1-1/4" cast iron pipe coupling and nipple to help press it on.

I got the rebuild kit from here: https://transpartswarehouse.com/bk2...nsfer-case-rebuild-kit-1966-1972-dana-20.html

After finding some scoring and excessive wear on the intermediate shaft, I ordered a "hardened" one from here: https://thejeepsterman.com/products...nsfer-case-1947-1986-willys-and-jeep-vehicles. It has not arrived yet so I hope it works for the Ford Dana 20.

I also ordered adjustable shift rail detents from JB fab.

Thanks for the detailed response!