Full Dana 20 Rebuild - Early Ford Bronco Build

Full Dana 20 Rebuild with Timestamps:
0:59 Layout
1:51 Rear Output Shaft Assembly
7:47 Shift Rail / Shift Fork Assembly
12:51 Front Input Assembly
19:54 Rear Output Installation
21:21 Idler Gear Assembly / Install
26:15 Detent Ball Install
28:05 Inspection Cover Install
27:12 Drain Plug Install
28:37 Input Shaft Discussion / Adaption
Dana 20 Rebuild PDF from Classicbroncos.com:
www.classicbro...
Dana 20 Kits and Parts from Wildhorses:
www.wildhorses...
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[@mutanthifi]

Fantastic video! I've been watching Dana20 rebuilds all evening as mine leaks like a government department and this one is the absolute most clear and useful I've watched! Next problem is getting parts in England............

[@alpinegarage8548]

Thanks for the kind words. Where in England?

[@mutanthifi]

@@alpinegarage8548 Hertfordshire, just north of London

[@rickolson9011]

Apppreciate the time stamping! Nice tight editing!

[@alpinegarage8548]

Thanks. Dana 20 in 30 minutes. Not accurate timeframe.

[@wildhorses4x4]

Very informative!

[@felixirlas7574]

I had a 96 gt40 explorer and i swapped in to a f150 90 and its been running good i think it needs a rebuild nice bronco.

[@clintanderson183]

Thanks for doing this. I’m about to do mine as well. I appreciate all the detail.

[@woowocgwhwrehvcb]

I'm going to do this next weekend!

[@diyjeff1838]

Great video!! Very thorough!!

[@henrymartens3322]

I noticed you didn’t reinstall the snap ring on the main drive shaft. Is that necessary to put back on?

[@jws227]

Thanks for video! Is there another video showing input shaft install? I’m doing seals and gaskets on mine, I pull off output shaft housing and found 10 shirt roller bearing drop by splined gear. Not sure where they go?

[@sarahgogal3455]

First of all, amazing video! I'm new to all things auto, new to your KZbin page and I'm finally beginning the restore of my 1971 bronco that i've hauled around for 20 years.. looking at the HD Rear Output Shaft Kit on Toms Offroad and was curious what the differences as far as install would be or if you even knew? thanks!

[@alpinegarage8548]

I don’t believe it would be any different. Same parts, different strength. Good luck.

[@jesseduke694]

I want to know about the dana 21. Not much out there for videos on the 21. I have sevral 21s but have never had a 20.

[@joaogamboa2885]

Hello sir, thanks for this video its beeing very usefull for my project on a dana 20. could u please tell me the length betwen the axles? Im currently projecting a dana 20 for my university project. Would apreciate any measurements even if its from the body outside. Nice work !

[@Michaelgosnell]

Is 80/90 Lucas Oil gear oil good to use?

[@sjwalker5696]

I wonder why the Dana 20 doesn't require felt gasket in between the seal and the yolk but the Dana 18 does I think it's pointless what are your opinion just wondering let me know thank you

[@alpinegarage8548]

Yes that’s interesting. I haven’t had any issues so far!

[@UnderSprayedWhiteSkies]

My brother has a 1972 Bronc and he says the transfer case is extremely hard to shift into 4wd. Please, is this a common problem for early Broncos, if so, is there a specific, part that's worn or misaligned?

[@alpinegarage8548]

Hard to say, but it may be metal and bushing material caught in the shift rail passage. That would cause it to stick and not shift well. Was it rebuilt recently?

[@UnderSprayedWhiteSkies]

@@alpinegarage8548 Thanks for replying, no, it's all original, never been overhauled. I think he has early style "T" handle shifter.

[@joedeveydt9977]

Great video. Can the dana 20 be built to drive front wheels only?

[@alpinegarage8548]

Instead of back wheels? Or just shifting from front to back?

[@joedeveydt9977]

@@alpinegarage8548 For front bumps while crawling

[@alpinegarage8548]

@@joedeveydt9977 yes if you take the detent pills out. I know this only from seeing it while building and on forums. The only issue is that it is possible to accidentally shift 2 lo in one axle and 2 high in the other. Then bang, there goes your tcase.

[@joedeveydt9977]

J shift style

[@alpinegarage8548]

@@joedeveydt9977 yep.