D20 transfercase

[68_Gladiator]

anyone know where i can get a rebuild kit for a D20 transfer case, looked on the internet but didnt find one? thanks

[gojeepin]

i can get you a rebuild kit,bearings and seals are pretty cheap.do you need any gears?thats a tuff t-case .unless its been run low on oil,just seals should be enough.

[68_Gladiator]

im not quite sure what it needs, but the shift lever flops allover the place its like its not attached to anything but ive got to replace headgaskets first before i take the t-case off, what would be the cause of the lever doin that?

[Dmntxn77]

Gaskets and Seals
http://www.bjsoffroad.com/cartgenie/prodInfo.asp?pid=79&cid=4

Master Overhaul
http://www.bjsoffroad.com/cartgenie/prodInfo.asp?pid=35&cid=4

As far as your problem is concerned.. It sounds like a linkage problem to me. Have you looked underneath at the shift rails? You might want to get under there, and have someone move the lever around for you. I am sure that the problem will be obivous.

[68_Gladiator]

well the rubber boot that surrounds it is missin so u can see the case while ur in the truck and then i move the lever nothin on the case moves so new linkage or maybe it just came off?

[Dmntxn77]

When you look down through the hole, you are not looking at the case. If that were the case, the lever would be under the seat. Instead, you are just looking at the linkage. I bet something just came loose.. Get under there, ant it will make sense.

[68_Gladiator]

okay cuz i saw 2 rectangle pieces of metal that i believe are supposed to move when u shift it but they dont, so if thats the case just linkage then? what would be the scenario if it still shifted into 4wheel but was still all loose and wobbly? still just linkage?

[Dmntxn77]

You really just need to get under there and look at it. You should not have to remove anything. You will however probably have to tighten or replace something. It is not a complicated set-up.. Just move the lever to the same position that the case is in and tighten what is loose. If there is nothing to tighten, take a good pic with plenty of light, and somone will probably be able to tell you what is missing.

As far as being in 4wheel with a loose linkage.. Are you asking if it is a problem? If so, it will only be a problem if you are only partially engaged or get stuck in an unwanted gear because the linkage is too loose to shift.

Your best bet is to fix the problem.

[68_Gladiator]

alright ill see if i can get a look at it soon, its still not at my house, its still sittin in the guys yard down the road

[Dmntxn77]

Ahh.. That makes getting under it a bit harder...

[tkiller13]

If this is the U shaped shift pattern, save yourself lots of time and future problems.. Search for....twin stick dana 20.

[shackwrrr]

Yea my u shaped setup puked a bushing in the shifter box and it did the same thing your saying. I converted mine to twin stick

http://i43.photobucket.com/albums/e357/shackwrrr/D20shifter.jpg

heres the shifter the shift rod bearings on mine disinigrated and let the shifter wobble around

[Dmntxn77]

I agree.. My twin stick was only $110 shipped and is a real nice set-up..

I just havent installed it yet...

It sure looks pretty on my floor though.. :D
http://i4.photobucket.com/albums/y130/dmntxn77/79%20Chief/Twin%20Stick%20Swap/Dana20TwinStick.jpg

[68_Gladiator]

im not familiar with what a twin stick does differently from a single, could someone fill me in? thanks

[gsmikie]

you could do this

[78J10honcho]

a twin stick set-up allows you to use low range independently from 4-wheel drive, basicly you have one shifter for 2 and 4 wheel drive and one for low range so you have these options
2-hi
2-lo
4-hi
4-lo
which is pretty handy if you need the gearing but don't need four wheel, it will be one of the next things I do after I finish my gauge cluster install

[68_Gladiator]

alright thatnks i understand now and it does seem like it would be a great upgrade from a single stick

[backroadin']

68 Gladiator: Here's most likely your loose shifter problem:
There are 4 small bolts that hold down the top plate on the shifter assembly. If you can't see them, remove the grease and dirt and you'll find them Tighten these down and you should have a much better shifter. If that doesn't work, then look elsewhere for problems, but start there first for sure. A 1/4 inch 12 point socket should do the trick - hard to find, but that's what it should need.
You can see these bolts in the diagram above from shacwrrr's post.

[Dmntxn77]

a twin stick set-up allows you to use low range independently from 4-wheel drive, basicly you have one shifter for 2 and 4 wheel drive and one for low range so you have these options
2-hi
2-lo
4-hi
4-lo
which is pretty handy if you need the gearing but don't need four wheel, it will be one of the next things I do after I finish my gauge cluster install

Thats not exactly accurate...

What you get is one shifter for the front and one shifter for the rear. So you actually have more options than listed above.
Your shift pattern would be like this:

Rear..........Front
Low...........Low

N..............N

Rear..........Front
High..........High

So, not only do you get the normal 2wd and 4wd high & low, you also get REAR ONLY high & low, and FRONT ONLY high & low.