replacing gaskets and seals in dana 20

[teknalee]

to replace the gaskets and seals do i need to remove the dana 20? and how hard of a task is this overall?

 

[swood]

Yes you need to remove the box. No it is not difficult, depending on how much of a rebuild you are doing.

You can tear the entire box down to the point where you have the input/rear output shaft kind of loose and sitting in the box. Everything else removed. Then you can replace all the seals. To remove this last shaft from the box entirely requires pullers and so on. All this can be done in a few hours after removal on the bench. Just get a good set of manuals (fordtoolbox.com) to follow.

One item to note are the shims that are used to set the gapping. If you are careful and don't pull apart that last shaft, you should be able to just put it all back together with the same shims and not have to do all the gap measurements and settings again.

Any bronco gods have any opinions on this?

 

[BlackHorse]

If you want to replace all the seals you might as well do a complete rebuild. In order to replace every seal you would need to disassemble the entire case including the shift rails. As it has been said how hard this is to do would depend on your experience. The 20s seem prone to leak so if that is the only problem you might just change the two output shaft seals and see if that fixes the problem. The cover gasket would be quick and easy too.

 

[teknalee]

well i'm just looking to stop the leaks.. it seems they're coming out of the rear output..should i really go through all the trouble?

 

[77TexasBronc]

Since the transfer case doesn't have any problems then just replace the rear seal. This can be done with the transfer case still in the EB and is a easy fix.