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The Original 3/8" Ruffstuff Diff Cover!Ruffstuff Axle Simple Swap Kit!The Ruffstuff NOT Universal 4 Link Kit!

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Unread 12-21-2015, 10:27 AM   #1
Stumpfarming
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Dana 20 intermediate shaft kits

I am about to order a new intermediate shaft kit for my Dana 20. I've noticed that the kit from Novak is more than double the cost of the Crown or Omix-Ada kit. Is the Novak kit that much better, or just overpriced? Does anyone have any feedback regarding the "lesser" kits?

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Unread 12-21-2015, 10:47 AM   #2
chromegrille
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You get in quality what you pay for....as far as intermediate shafts go.
Novak much better, harder shaft.
Forget the offshore junk unless you want to do the job over again in 6 months (or less).
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Unread 12-21-2015, 02:37 PM   #3
HackFabrication
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On a side note....

The intermediate shaft only goes into the case one direction. Don't try to put it in the wrong way!
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Unread 12-21-2015, 06:15 PM   #4
Partsmke
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Novak advertises "triple alloy". Here is the definition for 8620 Steel. This chromium-molybdenum-nickel "triple alloy" is a widely used case hardening alloy grade. Used where high surface hardenability and tough core is desired along with easy machinability and excellent wear resistance. The chromium and molybdenum contribute to hardness penetration while the nickel increases the toughness. Typical applications include: gauges, jigs, gears, piston rods, plastic molds, cams, pinions, spline shafts.
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Unread 12-21-2015, 06:16 PM   #5
82JeepCJ7
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I built a "Tool" on a lathe to hold the needle bearings inside the intermediate gear while the shaft was being inserted.... Saved a ton of frustration....
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Unread 12-21-2015, 07:06 PM   #6
Stumpfarming
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Thanks everyone for comments. It sounds like an extra $50 now will save me more than $50 in headaches later. :-) Yes, I am aware of the tapered shaft and even caught myself wanting to drive it the wrong way during disassembly. An easy mistake to make as I discovered. If I had access to a lathe, a "tool" would be a great idea. I'll give it a go with assembly Lube or Vaseline to hold Them in place when putting together, but I am guessing that tapping the pin in will likely dislodge a few of the bearings.
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Unread 12-22-2015, 06:34 AM   #7
jeepdaddy2000
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Quote:
I'll give it a go with assembly Lube or Vaseline to hold Them in place when putting together, but I am guessing that tapping the pin in will likely dislodge a few of the bearings
Grease works just fine.
again, insure you replace the thrust washers as well.
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Unread 12-22-2015, 10:23 AM   #8
Stumpfarming
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Quote:
Originally Posted by jeepdaddy2000
Grease works just fine. again, insure you replace the thrust washers as well.
Will do! The thrust washers almost look worn worse than the center shaft.
image-3128143932.jpg

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Unread 12-22-2015, 06:19 PM   #9
82JeepCJ7
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A short wood dowel works too.
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Unread 12-23-2015, 08:41 AM   #10
HackFabrication
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Quote:
Originally Posted by 82JeepCJ7 View Post
A short wood dowel works too.
That's the 'trick' I used when I rebuilt and added the TeraLow kit to mine:


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Unread 12-23-2015, 05:24 PM   #11
BeatCJ
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Quote:
Originally Posted by jeepdaddy2000 View Post
Grease works just fine.
Don't use grease. Use Vaseline, or assembly goo. Grease doesn't melt out at transfer case temperatures.
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Unread 12-23-2015, 06:43 PM   #12
Stumpfarming
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Quote:
Originally Posted by BeatCJ
Don't use grease. Use Vaseline, or assembly goo. Grease doesn't melt out at transfer case temperatures.
Yep. I've heard that from several sources and plan on following that advice. Thanks! :-)
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Unread 12-23-2015, 06:56 PM   #13
BeatCJ
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I have rebuilt a couple of Dana 300s using Novak Kits. It wasn't a bad job, they have excellent instructions. I don't know how much difference there is between the 20 and 300. I didn't need a holder/spacer for the intermediate gear needles, just Vaseline, it seemed like they almost snapped into place when I got the last one in.
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Unread 12-23-2015, 09:23 PM   #14
jeepdaddy2000
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Quote:
Originally Posted by BeatCJ View Post
Don't use grease. Use Vaseline, or assembly goo. Grease doesn't melt out at transfer case temperatures.
However did those hundreds of transfercases and transmissions I've rebuilt over the years ever survive.
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Unread 12-23-2015, 10:41 PM   #15
82JeepCJ7
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I should machine a bunch of them "tools" and make them available...
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