Transfer case removal question

[Silverhorse]

Can you remove just the dana 20 without removing the adapter or tranny from the bronco? I have always dropped the adapter and the t-case together, but I would like to just remove the t-case without dealing with the crossmember or tranny adapter.??

 

[grs44310]

The front input on the transfer case may stick in the adapter. If I remember right the adapter is the only thing that holds it in and there are bearings that will fall out inside the case. Sounds like more trouble than it's worth.

All in all, I vote remove the adapter with the transfer case. I have never seen a tech article or manual do it any other way.

Greg

 

[JohnJohn]

I pulled mine out no problem. Left the adaptor in.

The bearings stayed in place as well. This was with my body off the frame so the bolts were easy to get to.

 

[Silverhorse]

Well, The score is tied up at 1 each. I'll sit back and see how this goes!;D

 

[RajinCajun]

I have pulled mine without pulling the adapter a few times, only issue with not pulling the cross member is getting to the bolts. I usually pull the brackets from the frame and leave the cross piece in place since my exhaust is in the way from completely removing it, but it gives me room to wiggle it aroung to get to bolts and shifters. One less gasket to deal with in my book

 

[Bundy]

i agree it can be done, i think the bearings will just fall into the TC which are easy to get to if you pull it.

 

[Sweathog]

Whether correct or not, the stock 3-speed can be removed with the D20 left up in the frame. However, I split the adapter from the D20 - not the adapter from the tranny. I removed the crossmember bolts from the frame. With support from a ratchet strap I was able to move the D20 back far enough to pull the 3-speed. Right arm was in cast so I did not want to try and balance the D20 for the re-install.

 

[zeeman1]

I've swapped My Dana20's back and forth on my broncos and never took the adapter off with it. So far so good, never had any bearings fall or have anythying consequence at all doing it that way.

 

[broncotime]

I've swapped My Dana20's back and forth on my broncos and never took the adapter off with it. So far so good, never had any bearings fall or have anythying consequence at all doing it that way.

my bearings fell out when I separated the two and I had to fish them out with a flexible magnet. I guess I could have taken the inspection cover off, but the magnet ddi the job pretty quick.

 

[72-Madisyn]

I just got done with pulling my transfer case a few days ago and am wishing that I pulled the apdater with it. Bearings fell almost everywhere and it was just a pain. easy to pull either way but next time I am pulling all in one shot.

 

[zeeman1]

crazy, looks like I was just lucky.

 

[blubuckaroo]

Make it easy on yourself. Pull the radiator, the cross member and lower the case. Makes reassembly easier too.

 

[thegreatjustino]

If the transfer case snubber is still installed, you are not going to be able to access all of the bolts to remove the case. Other than that, it is a piece of cake to remove the Dana 20 and leave the adapter in place. The bearings should stay with the output shaft of the transfer case.

 

[Bituman]

Make it easy on yourself. Pull the radiator, the cross member and lower the case. Makes reassembly easier too.

Used this exact procedure two weeks ago. Worked really well.

Bob

 

[Silverhorse]

thanks guys! I'll post how it turns out.

 

[lobobronco]

Really want to see how this works out. If there is any tips...please post. I keep pulling the entire thing. Not a huge deal, but this would save time.

I did manage to make a nice jig to put the t-case (and adapter) back in....the wife only had to lift and lower the floor jack twice to stab it in.

On that note....I have an np435 with no body lift...will this change things? (hopefully this isn't a thread hijack)

Matt

 

[BRONC-OH]

I pulled mine without the adapter and lost 1/2 the bearings in the x-fer. Found all but one
Which caused me to tear the whole thing apart. It must have fell in the driveway.

 

[Silverhorse]

Buster S

"You can have this Bronco when you pry it from my cold dead hands"

LOL I love it!!;D

 

[Silverhorse]

Ok, Got the case pulled today. I just unbolted it from the adapter and left the adapter bolted to the tranny. Some of the bolts were hard to get to, I ended up removing the cross member to access the bolts. I supported the tranny by using a floor jack under the pan.
The bearings did stay in place so that was not an issue for me.;D

 

[mattt]

It can be done, just read this thread earlier and removed the D20 while leaving the adapter on the trans. A few things I will say......

The two bottom bolts would be impossible to get to with the transfer case snubber on the cross member. My snubber was ready to come out in about 46 pieces, so it came out and I then had access to the bottom bolts.

An easy way to reach most of the other 4 bolts is if you have an access panel from an old floor shifter. My EB has an aluminum cover panel(probably from an old 3 speed floor shifter conversion) on the drivers side tunnel. Without that panel I don't think I could have reached all the bolts from below.

If your tranny mounts on the crossmember are old and crusty, plan on jacking the D20 up just a tad to be able to get some of the bolts out. I have a feeling my tranny mounts are factory original, so they were a tad uh "squished." With the squish there it was only allowing some of the 6 bolts to come out 1/2 way before the heads were hitting the cross member. I put a little jack tension under the D20 and loosened the tranny/cross member bolts so the D20 would come up a bit. That gave enough clearance to get all the bolts all the way out. I'd imagine with all fresh rubber or urethane mounts some of these issues I dealt with wouldn't be there.

On my D20 the input shaft stayed in the transfer case so I had no bearing explosion. Sounds like the bearing explosion is if you leave the input shaft on the tranny output in the adapter.