Dana 20 to Ford 3 Speed install?

[Fordman23]

I attempted to reinstall a Dana 20 to a Ford 3 speed manual. When I bolted the adapter to the 3 speed it would not fit flush; I actually fractured the adapter housing and had to replace it. How do I get the Dana 20 mounted to the 3 Speed without a gap?

 

[jeffncs]

Dumb questions - you’re using the manual intermediate housing right? Not an auto housing? Did you change anything on the d20 (inout shaft?).

Mating surfaces should (obviously) seal tight.

Don’t force it. Make sure the alignment dowel and dowel hole line up. Also make sure that same hole is free of dirt/junk/?? so the dowel seats fully into the hole.

Are the d20 input and trans output lining up and seating fully? Make sure no burrs or random junk preventing a fully seated t-case.

Otherwise, there shouldn’t be much preventing the housings from mating up.

 

[thegreatjustino]

you’re using the manual intermediate housing right? Not an auto housing?

The C4 adapter won't even come close to bolting onto the three speed transmission. Completely different bolt pattern.

To the OP, is your output shaft installed correctly? If it has pulled out of the transmission, that amount of stick out won't allow things to line up and install as they should.

 

[DirtDonk]

And wouldn’t the best way to tell that, be to look at the rear output bearing to make sure that the outer snap-ring is flush up against the body of the transmission?

If that’s the case, and you can’t push the bearing up flush to the ring, then the shaft is extended, and you likely dropped a couple of roller bearings out of the input/output interface.
Meaning you’ll be taking the transmission apart to get it all back together.

 

[Fordman23]

And wouldn’t the best way to tell that, be to look at the rear output bearing to make sure that the outer snap-ring is flush up against the body of the transmission?

If that’s the case, and you can’t push the bearing up flush to the ring, then the shaft is extended, and you likely dropped a couple of roller bearings out of the input/output interface.
Meaning you’ll be taking the transmission apart to get it all back together.

. . .the output bearing extends about one half inch outside of the 3 speed case; if I remove the 3 speed cover could I find the roller bearings to see if thats the cause?

 

[Fordman23]

Dumb questions - you’re using the manual intermediate housing right? Not an auto housing? Did you change anything on the d20 (inout shaft?).

Mating surfaces should (obviously) seal tight.

Don’t force it. Make sure the alignment dowel and dowel hole line up. Also make sure that same hole is free of dirt/junk/?? so the dowel seats fully into the hole.

Are the d20 input and trans output lining up and seating fully? Make sure no burrs or random junk preventing a fully seated t-case.

Otherwise, there shouldn’t be much preventing the housings from mating up.

. . .this was the original set up with the right housings; the engine, tranny and t-case were just removed to aid in a restoration; the "302" was torn down due to rust in the cylinders and some roller bearings had to be reinstalled in the t-case; the 3 speed was left intact; if the 3 speed roller bearings could have been dislocated during the removal than that could be my problem . . .

 

[Fordman23]

The C4 adapter won't even come close to bolting onto the three speed transmission. Completely different bolt pattern.

To the OP, is your output shaft installed correctly? If it has pulled out of the transmission, that amount of stick out won't allow things to line up and install as they should.

. . .it's a 3 speed adapter; the output bearing sticks out about one half inch and that's not letting the adapter bolt up . . .

 

[Broncobowsher]

Two things come to mind on the first post. The output shaft pulling out and dropping parts was the first one, and sounds like what happened.
The next thing is the adaptor that you broke. There are 3 different versions (if not more). The I6 version is much shorter and would be obvious. But there were 2 different versions of the V8 transmission and a slight difference in transmission length. Which would be a slight difference in adapter length. I don't think that was the initial problem, but something to double check on the new part.

As for the dropping parts. Keeping the transmission in gear (the manual specifies a specific gear and a tool to lock it there, you can make your own tool if not just zip ties) to prevent that from happening. Not doing that is really common. As long as the transmission is in good shape it is nothing more than labor and maybe a sheet gasket for the top cover. And you get to inspect the innards and consider refreshing it if things look worn.

 

[Fordman23]

Two things come to mind on the first post. The output shaft pulling out and dropping parts was the first one, and sounds like what happened.
The next thing is the adaptor that you broke. There are 3 different versions (if not more). The I6 version is much shorter and would be obvious. But there were 2 different versions of the V8 transmission and a slight difference in transmission length. Which would be a slight difference in adapter length. I don't think that was the initial problem, but something to double check on the new part.

As for the dropping parts. Keeping the transmission in gear (the manual specifies a specific gear and a tool to lock it there, you can make your own tool if not just zip ties) to prevent that from happening. Not doing that is really common. As long as the transmission is in good shape it is nothing more than labor and maybe a sheet gasket for the top cover. And you get to inspect the innards and consider refreshing it if things look worn.

Thanks for the comments! The 3 speed adapter replacement is identical to the original; so guess I will have to dig into the 3 speed and see if I can return the output bearing to the case of the 3 speed; also sounds like I need to shift to a certain gear configuration during the install. . .