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Dana 20 Internal Question

Discussion in 'Intermediate CJ-5/6/7/8' started by johneyboy03, Mar 26, 2017.

  1. Mar 26, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    I'm working on my dana 20 transfert case. I dont know if that normal but the intermediate gear is having a side play, about 3/16" front to rear.

    It cause that front and rear output gear to misalign causing the gear to have a 50% contact each other.

    I got 3 other dana 20 t case dans two of them doesnt have this play on the intermediate gear and the other one have exactly the same play as the one on my jeep.

    Is there something i can do about that?
     
  2. Mar 26, 2017
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    I'm not real familiar with the 20 but, my first guess would be that the thrust washers are missing from each end of the int. shaft/gear, if it is supposed to have them in the first place. Has the t-case in question been rebuilt at some point and the rebuilder left out the thrust washers?
     
  3. Mar 26, 2017
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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    [​IMG]

    I would say dave might be right . thrush washers worn or gone
     
  4. Mar 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Thrust washer are there, but as you said i might be worn out so leaving a gap in the idler gear.

    Juste to make sure the idler gear is suppose to be in place without any noticeable play?
     
  5. Mar 27, 2017
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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    correct . no side play
     
  6. Mar 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    So i write an email to novak adapter, i will get a rebuit kit for the idler gear with a gasket kit.

    I will order a twin stick set-up. my current shifter all the moving part axle worn out and may not help to get a fulley engage t case.
     
  7. Mar 27, 2017
    CJ5Jeeper

    CJ5Jeeper Teacher Jeeper

    Apple Valley, CA
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    Jan 28, 2015
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    Good move getting the twin stick from them. I've been really happy with their set-up.
     
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  8. Mar 27, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Oct 6, 2003
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    The NOVAK twin kit looks just like my JB Fab one.. Good stuff.. I installed mine while the Tcase was in place, had to do a bit of tweaking but it works so much better than the OEM Rube Goldberg single stick deal..
     
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  9. Mar 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    I have the transfert case tore appart so it will an easy swap...i hope so. Just waiting for a quote so i can place an order.

    thank's
     
  10. Mar 27, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    I think the NOVAK is cheaper than at JB Fab,.. Looks exactly the same though..
     
  11. Mar 29, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Finaly, i did order from advance adapter a kit of tapered bearing to replace the roller bearing on the intermediate shaft. Price for Oem or this kit is the same but AA suggest me the tapered bearing kit that will reduice noice and wear to the thrust washer.

    As soon as i get them i will do a post about it, it can help other that has the same problem as me.
     
  12. Apr 1, 2017
    CJ5Jeeper

    CJ5Jeeper Teacher Jeeper

    Apple Valley, CA
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    I ordered my twin stick conversion through Novak, but all the parts seemed to be manufactured by JB Fab. I was happy with the quality.
     
  13. May 10, 2017
    jpet

    jpet New Member

    Ramsey, IL
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    Nov 13, 2010
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    Did you machine the counter bores in the intermediate gear yourself? How did that go? I have the same kit but the local shops say the gear is too hard to cut.
     
  14. May 10, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    You may need to look over another machine shop. Did you provide the instruction from AA to you're machine shop. It said in there : Due to the extreme hardness of the gear, several cuts will need to be made in order to obtain the correct measurements.

    The shop i gave them the intermediate shaft didn't have any problem doing the job and never mention me they have a hard time doing it. Advance adapter told me they are been seeling this kit for more than 25 years....

    Here a picture of the actual gear machined. If they don't believe you just show them this picture.

    17917059_10154227468911621_1381269224_o.jpg
     
  15. May 10, 2017
    jpet

    jpet New Member

    Ramsey, IL
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    Thanks! I'm going to cut it myself. I was looking for some confidence before I start cutting. Once I start, there's no turning back :)
     
  16. May 10, 2017
    oldtime

    oldtime oldtime

    St. Charles,...
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    Jeff you cutting into your Tera low gear set already ?
    Your Tera flex intermediate shaft give out already ?
    I just sent a brand new Tera flex gear down to McRuff to bore it for the tapered bearings.
     
  17. May 10, 2017
    jpet

    jpet New Member

    Ramsey, IL
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    No, it's not wore out. The TC has always been pretty loud when in low range 2nd and 3rd gear. I was always afraid it was giving out so I ordered the tapered bearing kit. Yesterday, I pulled the cover and dropped the intermediate gear. Everything looks good. Gears, intermediate shaft. I guess they are just noisy. I'd like to eliminate as much noise as I can.
     
  18. May 10, 2017
    oldtime

    oldtime oldtime

    St. Charles,...
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    Yeah I'm afraid most of that noise comes from the 3.15 gear set that your running.
    Very interested in your opinion concerning the noise reduction after you install the tapered bearings.

    For starters I'm going to run tapered bearing 3.15 gears in a D-18 plus O.D.
    I know that combo will be noisy without the tapered bearings.
    I also have later plans to run another set of tapered Tera flex gears in a D-20 .
    Curious to know if its worth the extra effort concerning noise.
     
  19. May 11, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    I'm getting my twin stick from novak today, so i will install everything this week-end and hopefully get a trail test over it. Can't wait to see the improve over factory needle bearing.
     
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