Dana 20/t-15 Bolt Up

So a bit of a problem, I am bolting the transfer case to the t-15 and the tighter I bolt them together the less the transmission will move in neutral, I can stop it from moving when fully torqued

 

Did you take the T-15 apart? How about the transfer case?

 

Both, transmission doesn’t turn freely in every gear

 

Transfer case turns in all gears like it should, linkage a little tight but I think expected till gear oil really gets moving in it?, I don’t have a diagram of the t-15, can’t find one anywhere, used the t-14, seemed pretty similar

 

I can’t understand how I can put it in neutral, and a couple gears and it works fine, just not all

 

What year is your Jeep? You should put the year and equipment in your signature file so that it's present for every post. It almost always matters. Some TSMs lump the T-14 and T-15 together. The '77 or '79 TSM on the www.oljeep.com site will show the T-15 by itself, but that's mostly because the T-14 was gone by then.

When you say couple of gears, which gears exactly? Does the countershaft turn?

Just off-hand, if tightening the transfer case to the transmission freezes everything, I'd think the overall length of the mainshaft or input shaft is wrong because of either wrong parts or improper assembly. What did you replace, and who supplied the parts?

 

Something in the transmission either not fully seated, assembled reversed like a synchronizer assembly, or the rear bearing spacer installed in the wrong spot. Been a long time since I’ve been in a T-15 so the last may not apply, but I know it does in T-14’s,T-90’s, T-86’s, etc.
one of the pocket needle bearings between the input and output out of place can cause the output to be pushed too far back and cause it as well.

 

This is T-15

 

1974, Countershaft turns great, I can put it

Everything thing “seems” correct! It’s just like the shifter isn’t in the right place when you go through the gears, moves around great, the main shaft just doesn’t turn in most shift positions. I stumbled across a note in the TSM, says that the snap rings for the main shaft bearing snap ring is 0.010 thicker than the main drive gear bearing snap ring. Could that cause the problem? Almost seems like the main drive gear bearing may not be pressed on all the way, it seems like the bearing cap is as close to the transmission as it can be, maybe it just seems that way? Your needle bearing suggestion that one may have fallen out and is stuck in the end of the front output shaft, would that not let the transmission seat all the way into transfer case? Cause it not to turn? And furthermore not allow for the transmission to shift in all gears?