Question for all you Dana 20 experts:
A little background: 1967 J3000 w/ 327, T18, Dana 20, Dana 44 front and rear. Newly rebuilt Powrlok in the rear, new rear axles (full floating).
I had the original J shifter on the Dana 20. Occasionally, it would drift out of 2 HI into neutral, not a huge deal. Eventually, this seemed to get worse. I thought there were issues with my new rear axle rebuild, but everything checked out. I then put a twin stick conversion in last November, which made things worse. Ordered a new rebuild kit for the 20, put it in, now the thing will barely stay in 2 HI and immediately pops out of 4 HI and Low. I pulled out the case again, opened it up, can't see any real problems. I did order a new output gear off the T-18, since one of the teeth was broken. Poppet springs and balls were replaced and heavily shimmed with washers. Replaced the bearings, intermediate shaft and thrust washers, seals and gaskets. End play is good on front and rear output. Shift rails are perfect, no wear on them. I shimmed the hell out of the detent springs. Everything went back together nicely.
I got the case back in the truck, started it up and drove around for a while. I was on the freeway, when bam, came out of gear again. Could not get it back into 2wd. So I switched to front wheel drive only and drove home. When I got back, my rear wheel drive was working again.
I have no idea what I'm doing wrong. I don't know if there is a gap between the rear output gear on the transmission and the rear output shaft, because that's where rear 2wd high is engaged.
Thoughts? Who else has had this problem?
A little background: 1967 J3000 w/ 327, T18, Dana 20, Dana 44 front and rear. Newly rebuilt Powrlok in the rear, new rear axles (full floating).
I had the original J shifter on the Dana 20. Occasionally, it would drift out of 2 HI into neutral, not a huge deal. Eventually, this seemed to get worse. I thought there were issues with my new rear axle rebuild, but everything checked out. I then put a twin stick conversion in last November, which made things worse. Ordered a new rebuild kit for the 20, put it in, now the thing will barely stay in 2 HI and immediately pops out of 4 HI and Low. I pulled out the case again, opened it up, can't see any real problems. I did order a new output gear off the T-18, since one of the teeth was broken. Poppet springs and balls were replaced and heavily shimmed with washers. Replaced the bearings, intermediate shaft and thrust washers, seals and gaskets. End play is good on front and rear output. Shift rails are perfect, no wear on them. I shimmed the hell out of the detent springs. Everything went back together nicely.
I got the case back in the truck, started it up and drove around for a while. I was on the freeway, when bam, came out of gear again. Could not get it back into 2wd. So I switched to front wheel drive only and drove home. When I got back, my rear wheel drive was working again.
I have no idea what I'm doing wrong. I don't know if there is a gap between the rear output gear on the transmission and the rear output shaft, because that's where rear 2wd high is engaged.
Thoughts? Who else has had this problem?
