Transfer Case Rebuild

[71 Red Bronco]

I'm rebuilding my D20 due to popping out of gear in 2Hi. The rear output sliding gear and shift fork appear worn. Does anybody know the correct measurements for the width of the shift fork where it sits in the groove on the sliding gear? Also how wide is the groove supposed to be. The front shift fork and sliding gear are much tighter. I'm guessing that I need a new sliding gear and fork for the rear.

 

[mpboxer]

Bump to the top for you. Interested as well.

 

[WheelHorse]

The popping out is usually the pills and springs. Most recommend starting there before anything else. Check the the rods where the pills ride.

Hopefully someone with a disassembled D20 has that measurement for you.

 

[hammer189]

https://jb-custom-fabrication.myshopify.com/

Check out these guys. They sell new shift rails and spring ball detents. They also sell a twin stick set up. Bought it all recently. Really well made! You should call them, they answered all my dumb questions.
David

 

[Justafordguy]

X2 on the JB-Fab stuff. Great parts and super good people.

 

[sykanr0ng]

https://jb-custom-fabrication.myshopify.com/

Check out these guys. They sell new shift rails and spring ball detents. They also sell a twin stick set up. Bought it all recently. Really well made! You should call them, they answered all my dumb questions.
David

They now have new Dana 20 shift interlock pills too.
Custom made and heat-treated.

Excellent quality. (I am a machinist myself)

 

[71 Red Bronco]

I have the JB Fab Twin Stick. I also have the adjustable shift detent kit. Both installed prior to starting my rebuild. Still popped out of gear under acceleration or a heavy bump. I have the case completely disassembled and am replacing all seals and bearings. Two of the rear output shims were disintegrated. That was probably part of the problem. I also noticed the rear shift fork was worn considerably more than the front along with the groove in the gear. I just was not sure how important it would be for the shift fork and gear to fit with the correct gap. Now that I've looked closely at the rear sliding gear I noticed one of the teeth has a chip. I'm leaning towards replacing the gear and shift fork. The rest of the T-case is in excellent shape.

 

[m_m70]

I also noticed the rear shift fork was worn considerably more than the front along with the groove in the gear.

This is what caused mine. Replaced and no issues in 24k miles

 

[Hickboy727]

Hey guys how tight was the intermediate shaft with new thrust washers when reassembled? Mine I can barley turn, its all lined up, I assume it will wear in the brass thrust washer but want to make sure before I close it up.

 

[Slednut10]

Mine was fairly tight when I rebuilt it this spring. The new washers and the sticky assembly grease made it tough to turn by hand.

 

[74 Bronco Billy]

Ditto that, very tight with assembly goo and tough to turn. My tranny guy said that was fine, more important that you can move shift fork well. Make sure you use the right oil for break in as well.