STUCK, Cant Get the Dana 20 Transfer Case on

[Crainbow243]

So I just did the clutch and the transmission and adapter are in the car, but to get the tranmission back up there I had to seperate it from the transfer case. Now I am stuck with not being able to get those small needle bearings back onto the shaft. Issue one is I have 13 of them... how many are there suppose to be?

Issue two is getting them aligned around the shaft, How do I get the shaft to remove from the adapter? easy to do? Is that the best course of action to get this transfer case back in?

Here are some pictures of where I am at... In the garage now working on it.

 

[Crainbow243]

Shaft still in trans/adapter that I think I should be able to remove: HOW DO YOU REMOVE THIS SHAFT?

 

[Crainbow243]

Where shaft has to insert into transfer case:

 

[Crainbow243]

Little needle bearings... I have 13... how many should there be in a DANA 20?

 

[Bonco4Broncos]

I have not cone this but have read that you use grease and align the bearings in the transfer case. The grease holds the 13 bearings in place whil you slide the tranfer case onto adapter. Hope this helps and that some one more knowledgeable speaks up soon.

 

[Crainbow243]

I found this picture, Is mine going to be similar to this in that it looks like it just slides out?

 

[Crainbow243]

I have not cone this but have read that you use grease and align the bearings in the transfer case. The grease holds the 13 bearings in place whil you slide the tranfer case onto adapter. Hope this helps and that some one more knowledgeable speaks up soon.

Yeah we thought of that, but the transfer case would be on its side... not on its back so it would be real tough to line them up. That is why I am thinking I have to remove the shaft from the adapter first.

Do you know that it is 13?

 

[Rustytruck]

I am guessing you have an automatic. There is a seal cover with a double lip seal holding the input shaft inside the adapter. That cover has an o-ring around the outside. The input shaft with the gear just pulls out off the end of the transmission spline. If you have 13 roller bearings you have all of them. Clean the oil off them and the end of the shaft cup. slap in some sticky grease on the rollers ans inside the cup. Stack the roller bearings in the cup that will hold them in place. Since you are in this far it is advisable to replace the special double lip seal and O-ring. Buy the double lip seal from one of our vendors as it is common to order the seal from the local auto parts and get the wrong single lipped seal which fits but wont work properly.

 

[Rustytruck]

Sorry I see you have a manual tranny.

 

[fm742]

I have found it easier to install adaptor onto the xfercase, then onto the trans.

 

[bax]

Yes 13 rollers. yes that shaft will pull out of the case. But you dont have to do that way however it is easier to just install the shaft into the case and then into the intermediate . install the beasings with some grease to hold them in place. the last bearing will install by sliding it into its space. nor trying to force it in from the side.

 

[Crainbow243]

Does the sealed bearing come out of the adapter? Or does that stay in? I'm having trouble pulling it out

 

[Crainbow243]

Does 1 separate from the adapter? Or just 2?

 

[Viperwolf1]

Just 2 on a manual adapter.

 

[Crainbow243]

How does 2 slide out from one? Looks like a snap ring is on that bearing, do I have to remove that snap ring? Does the brearing behind that big gear come out?

 

[Crainbow243]

So got the shaft out but had to remove a snap ring holding the bearing into the adapter. Once the shaft is in the transfer case how do you get that snap ring back on?

 

[Viperwolf1]

So got the shaft out but had to remove a snap ring holding the bearing into the adapter. Once the shaft is in the transfer case how do you get that snap ring back on?

You can't. The only reason to take it apart is to replace the seal or bearing. It has to be all together to go into the tcase. Put the 13 roller bearings into the hollow end of the output shaft (the part that's inside the tcase), put a gasket on the adapter, then slide the tcase over the gear on the adapter. Keep it going straight and the bearings will be fine. Try to put it on crooked and the bearings will move out of place.

 

[Crainbow243]

Well I ended up just taking the adapter off the trans (which was on the car) and mounting it to the t-case... didnt think the bearings would hold if the t-case was on its side. It all worked out and the bronco is running and driving now!!!! Ill update when I get more info on problems. Didnt realize that the bearing would have to snap-ringed in... kinda killed my plan of just mouting that shaft to the t-case.

Thank you guys for all the help!!! Sorry I was so frantic, just needed to get it running today.