post #1 of Old 01-22-2006, 01:15 PM Thread Starter
dreski1
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Dana 20 Rebuild - Help

I began disassembling my Dana 20 Transfer Case and was stopped cold by a Alen Set Screw that will not budge. The set screw is on one of the shifter rods holding a shift fork in place. I cannot get that thing to move and it is preventing me from removing the front bearing cap. I am following Novak's instructions and I have committed myself to getting this thing done correctly.

I soaked the screw in PB Blaster last night and even put some heat to it today, but no luck.

Any help would be much appreciated.

Thanks,

Dave


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86 CJ w/ 91 YJ tub, V8 304, , HEI, T150, ACM20 w/ 33's. Chili Pepper Red.
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post #2 of Old 01-22-2006, 07:00 PM Thread Starter
dreski1
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OK, this thread isn't getting the response I had hoped. So let me ask another question. The set screw is a 3/16" alen. How far can I twist the alen wrench before is fails? As I am getting after this thing, the wrench will twist about 90 degrees. It hasn't failed yet, but can I expect it soon or should I continue to twist until either the screw or wrench lets loose? I am not sure I have any other choices.

Thanks again,

Dave

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86 CJ w/ 91 YJ tub, V8 304, , HEI, T150, ACM20 w/ 33's. Chili Pepper Red.
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post #3 of Old 01-22-2006, 07:10 PM
BESRK
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Are you using one of those 90 degree Allen wrenches? If so, toss it and go buy a set of Allen Head Sockets that you use with a 3/8" ratchet. That will allow you to put more uumphh into it.

'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..


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post #4 of Old 01-22-2006, 08:15 PM
gumby
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use a torch to heat up the metal...disimular metal and galvanic action sometimes welds them together. also if you can hit them a few times to break up the bond between the two halfs

1984 CJ-7 offroad special loves to get dirty and play rough. unlike the girls I meet
258 rebuilt with torquer cam/ weber 32/36 carb, HEI ignition ,headers 4 in lift AMC 20 detroit rear locked and trussed / tru trax front 4:56 Gears ,solid axles on 35's

"Two roads diverged in a wood and I - I took the one less traveled by, and that has made all the difference."-
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post #5 of Old 01-22-2006, 08:17 PM
gumby
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use a torch to heat up the metal...disimular metal and galvanic action sometimes welds them together. also if you can hit them a few times to break up the bond between the two halfs.... just read the fact you used heat.. beat it like a redheaded stepchild. like a drum...like your johnson after prom

1984 CJ-7 offroad special loves to get dirty and play rough. unlike the girls I meet
258 rebuilt with torquer cam/ weber 32/36 carb, HEI ignition ,headers 4 in lift AMC 20 detroit rear locked and trussed / tru trax front 4:56 Gears ,solid axles on 35's

"Two roads diverged in a wood and I - I took the one less traveled by, and that has made all the difference."-
Robert Frost
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post #6 of Old 01-22-2006, 08:51 PM Thread Starter
dreski1
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The beating part I can do. I just don't want to go blind.

I tried heating this morning, but was a little hesitant to get too crazy with the heat because it is a gearbox that was recently full of oil. I was afraid that it might "flash". I will try the alan socket next and then the heat if that doesn't do it.

Thanks for the help.

Dave

____________________________________________
86 CJ w/ 91 YJ tub, V8 304, , HEI, T150, ACM20 w/ 33's. Chili Pepper Red.
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post #7 of Old 01-22-2006, 09:57 PM
jeepdaddy2000
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Go buy an impact driver and a quality 3/8ths drive allen in the right size. Place the allen wrench in the bolt and give the driver a couple of smacks.
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post #8 of Old 01-22-2006, 10:04 PM
mud4me
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I am very familiar with the internals of the Dana 20.

As others mentioned, you need a decent, professional socket for hex bolts.

Also, if using heat - do not heat the bolt! heat the object that holds the bolt.


Good luck. Its an easy rebuild once you get those hex bolts free.

86 CJ-7, 360, Holley Avenger, T-18, Dana 20, 4" suspension,
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post #9 of Old 01-23-2006, 05:55 AM
CJ51973
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The impact driver will do it. I have had one of these things for ever. It also shouldn't strip out using this. The last resort will be drilling it out.

Anything is possible if you don't know what you are talking about.
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