dana 20 twinstick interlock alternatives

[661buster1963]

I spent quite some time looking at the many well written explantion articles on how to grind for interlock pin useage on a twinstick dana 20. Went as far as printing some of the pictures and cut them out and slid the rails into any and all combinations available. Unfortunately the two bad conditions that scare me are front in low rear in hi, and front in hi and rear in low.

Near as I could tell the most popular mods seem to be to take the ramp out of the rear rail where the detent ball and spring ride for low range and maybe keeping the rear rail from popping out of low. Then grind a little on the rear rail where the interlock pins ride; extending the section behind hi gear down to neutral, and then extending the other pocket from its current location up to the low position, leaving a small section between neutral and low for interlock.

It seems that at least one 'bad' conditions can still be acieved, If I put rear in low I could move front to high with no interlock, so I was wondering if anyone has done it, or maybe why it would not work to:
go ahead and just take the interlock pins out and create a bar to be used external of the transfer case with some oblonged holes in it such that it can be mounted in each shift rail using the holes there already (maybe not in the slot but likely below the rail) such that the oblonged hole diameters will allow the closest combination of neutral and neutral or hi and hi or low and low, and those next group longer dimensions including neutral and high or neutral and low. and basicallys just not allow the two most extreme dimensions noted above as the 'bad' ones.

I dont worry so much about myself jacking the tcase up, as I have belabored this now for weeks to find an easy fix, but on the rare occasion I may when truck is complete lend it to a buddy who might have the philosophy of 'go full throttle to either cure the problem or end the suspense'

 

[73azbronco]

You "loan" your truck????

Easy, tell him not to touch nothing he don't know what it does. He breaks it he buys it

 

[Viperwolf1]

I spent quite some time looking at the many well written explantion articles on how to grind for interlock pin useage on a twinstick dana 20. Went as far as printing some of the pictures and cut them out and slid the rails into any and all combinations available. Unfortunately the two bad conditions that scare me are front in low rear in hi, and front in hi and rear in low.

Near as I could tell the most popular mods seem to be to take the ramp out of the rear rail where the detent ball and spring ride for low range and maybe keeping the rear rail from popping out of low. Then grind a little on the rear rail where the interlock pins ride; extending the section behind hi gear down to neutral, and then extending the other pocket from its current location up to the low position, leaving a small section between neutral and low for interlock.

It seems that at least one 'bad' conditions can still be acieved, If I put rear in low I could move front to high with no interlock, so I was wondering if anyone has done it, or maybe why it would not work to:
go ahead and just take the interlock pins out and create a bar to be used external of the transfer case with some oblonged holes in it such that it can be mounted in each shift rail using the holes there already (maybe not in the slot but likely below the rail) such that the oblonged hole diameters will allow the closest combination of neutral and neutral or hi and hi or low and low, and those next group longer dimensions including neutral and high or neutral and low. and basicallys just not allow the two most extreme dimensions noted above as the 'bad' ones.

I dont worry so much about myself jacking the tcase up, as I have belabored this now for weeks to find an easy fix, but on the rare occasion I may when truck is complete lend it to a buddy who might have the philosophy of 'go full throttle to either cure the problem or end the suspense'

It's already been done.

 

[Skiddy]

I have in a hurry mixed them up, not too bad to get out of a bind. worse case unlock the front hubs

 

[Nevadasmith]

Check out jb fabs, New d20 shift rails, specifically designed for twin stick with an external interlock link, you get all the good options, and none of the bad....plus I think they are still on sale I just bought some and hope to have them installed tomarrow

 

[Nevadasmith]

Also there is a YouTube vid on diy external interlock link

 

[JB Fab]

The external interlock bar will not do it by it's self. The distance the shift-rails travel form the neutral position is not the same each direction.

 

[JB Fab]

Here is a link to our solution.

Promo code EB20SR15 for 15% untill July 1st

https://jb-custom-fabrication.myshopify.com/collections/shift-rails/products/ford-d20-shift-rail-kit

 

[bigmuddy]

JBFAB
Do you need an extra pill to make this work with your kit and a D20 J case?

 

[JB Fab]

JBFAB
Do you need an extra pill to make this work with your kit and a D20 J case?

Yes you will, but we are having 500 made if locating one is an issue.
we should have them in 3-4 weeks.

 

[74 Bronco Billy]

Just received my kit from JB, as well as the twin sticks he has....very nice quality, everything sealed in heavy plastic and labeled very well. You can look through every bag with out opening them to make sure all parts are there. Buy enough and he might throw in a cool key chain bottle opener.