Hello, I have a '72 EB with a Dana 20 T/C bolted to a C4. The problem I'm having is there's a clicking sound I hear, at least at low speeds. It sounds like a playing card hitting the spokes on a bicycle wheel. I can't figure out what's going on for the life of me. It also is engaged [2WD] even when it's supposedly in the {N} Neutral position. I've had plenty of old CJs that, when in the neutral position, everything is dis-engaged. Is this normal operation for a Dana 20? This transfer case is a major pain to shift into 4WD or 2WD. I've checked the level of the gear oil, and it all checks out. Also, the truck has Superwinch lock-out hubs on it if that helps at all. Any and/or all help would be GREATLY appreciated!!! Chad76

 

No this is not normal. The D20 shifts like any Good tcase. Nothing funny when it is in good mechaniclal condition.
Something is wrong internally, i'me sure.

 

Ya it is messed up. In the past i have messed up transfercases when i mud bog and thats what happens if they don't go all the way out. but usally the gears for me just blow a part but some times it starts out with nouises and it is hard to shift it, then it takes a crap on u after a while.

 

Thanks for the info. I do some wheeling, but nothing TOO extreme. That being said, would I be better off in the long run to go ahead and rebuild the D20, or just bite the bullet and put in an Atlas...? Pending on price for overhaul kit for D20. Would an Atlas be TOO MUCH for what I use it for? Thanx, Chad76

 

D 20 is tough and parts are still preatty easy to get. I have had no problem with mine and it has taken a thrashen.

 

Thanks for the parts icon. Would I want the bearing and seal overhaul kit or any of the shafts? ie:[Idiot in the transfer case department]. Is the difficulty meter on the D20 as much as a C4 rebuild? Thanx, Chad76

 

It is not difficult if you lay everything out as you take it apart. I can't guess what parts you will need but I have a good Chilton rebuild manual I could copy for you if you need it.

 

ya the there a tough transfercase, its just that mine gets a hell of a beating with all the power being dumped though it, and the 40 inch Ground Haws tires really get a lot of grip in the mud.

 

I appreciate all the input on this thus far. I went by a couple of transmission shops today and they ALL said "the chain is messed up, and that THEY would have to completely rebuild the whole thing and maybe the C4 as well". I thought that year Dana 20 was gear driven?? It's tough to find a decent "mechanic" who won't try to take all your money, and actually knows what the hell they're talking about. No one would ever give me a straight answer as to the symptoms of what it could maybe be. I had planned on fixing the thing myself anyway, I just need to familiarize myself with the internals and where to start. I've looked all over the .net trying to find any troubleshooting hints for my symptoms on the Dana 20, but to no avail. I'd hate to completely overhaul the whole thing only to overlook something maybe small that needed repair in the first place. Thanks also for the Chilton copy offer, I've already downloaded one. This '72 has a 302 roller motor out of a '93 LX 5.0 less EFI. Edelbrock top end and long tubes. 4.56 gears turning 35" Regul M/Ts. It's MEAN, but not worth a crap if I can't distribute the power to the driveshafts. ONWARD.....

 

chad76, I'm running a 340 horse 351W crate engine and my D20 Tcase has worked flawless for the last 10 years. No chain, it is gear driven. I would just call an outfit like Toms Bronco Parts and see what they get for an exchange. Then compare that to messing with it yourself.

 

68 351 Bronc,

Thanks for the info. I'll call Tom's tomorrow and maybe get something worked out.

 

ya i have a 428 ceveland corba jet that is 400+ in my 69 Bronco with 40inch tires and i have never had a problem with my transfercase And you can put it in 4X4 on the road and smoke all for tires, some times if u dump the cluch hard it does a wheelie. I think that the reson my transfercase goes out in my 72 mud bogger is because i have heavy duty Axles,Gears,driveshafts, and a C6 transmission. It is the only stock drive train part on my truck.But i break more Dana 60 fround and rear ends and driveshafts than i do my Transfercase.

 

Chad it sounds like you have a bent shifter fork, this would cause the problems you describe. What's your location , If its not too far I could repair it for you.
As for parts I use Cresson Ridge Diesel , Cresson Pa. They are a Spicer dealer.
The phone # 814 886-4164. I possibly have some used parts to fit your T case.
Let me know if I can Help.

Have A good day --------- Hotwrench

 

It sounds like from all of you guys experience, the D20 T/C will DEFINITELY hold up to hardcore power and abuse; worth it's weight in gold. I'm out of Ocean Isle Beach N.C. right above the N.C./S.C. LINE. That might be a little far to mess with from PA.? If you have any used parts [shifter fork, & others needed to perform task], I could possibly purchase these from you along with some advice on how to install it. If it's not too far however, I would DEFINITELY appreciate the repair, pending on amount $. I checked out an exploded view of the Dana 20 on the .net, and I would not know if I needed the shift rail seals and/or other parts as well? Please contact me either via here or 910 477-0136. THANKS ALOT!!! chad76