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?
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.
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.
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.
There are some things you will learn while holding a cat by the tail that can be learned no other way...