Jeep CJ7 Dana 20 Transfer Case Removal

Fairly straight forward video on how to remove the Dana 20 Transfer Case that is paired up with the T150 3 speed in my 1979 CJ7. Few bolts, a little effort and some problem solving and off it comes.

[@peterbiltpusher]

I really appreciate the time you spent documenting all of these individual projects on here. I’m overhauling my 79 CJ right now and finding it very helpful!

[@coolguy_CJ7]

Excellent to hear. When you get a chance let me know which one of the videos you find the most helpful. It's always good to get feedback.

[@peterbiltpusher]

@@coolguy_CJ7 so far the t-150 tear down. Not a lot of great stuff out there for that one specifically as most folks don’t keep it, or interchange them. I’m trying to keep mine largely original as long as the body lasts.

[@peterbiltpusher]

Also, great tip on upgrading/restoring the switch/instrumentation lights!

[@coolguy_CJ7]

You are correct on the T150. I know it's only a 3 speed but it's a really durable and strong transmission. The only thing I would swap it out with is the T18, but good luck finding one of those. And thanks for keeping yours original. Not many of us left anymore. :)

[@jasonshiveley3820]

I'm in the starting stages of restoring a 1979 CJ7 and your videos are gonna be a hugh help to me... much appreciation for them.

[@coolguy_CJ7]

Glad to be helpful. Reach out if you need.

[@jasonshiveley3820]

I definitely will, I appreciate it

[@suehendry9132]

Love watching your instructing and actual workings. Put those safty glasses on!

[@truck93]

I just rebuilt my T150 and D20 on my 77 CJ7. While I was at it, I upgraded to a twin-stick transfer case selector. The stock binds too much with the play in the linkages, and no replacements out there. It's worth it and looks clean.

[@coolguy_CJ7]

Interesting. Did you do the rebuild yourself?

[@beestoe993]

Just what I was looking for, removing my T/C today. So there are a total of 6 mounting bolts then. ?? Thanks for the tutorial.

[@coolguy_CJ7]

Sorry so long in response, but with that sneaky on in the lower center area, it makes 6 total. Also, update!!! I found that you can almost easily access that bolt from down below. So try that instead of going at it from the front.

[@JohnSmith-sf8gj]

I am going to assume that with the body on you would remove the skid plate/trans support first, while supporting separately the engine/trans, then remove the trans and transfer case as a unit with a trans jack. Because I can't see getting that top transfer case bolt out at 6:25 without big frustration with the body on. Wrong?

[@coolguy_CJ7]

Could be. I don't have my body tub painted yet otherwise, I could give you an accurate assessment of your question. But your cadence of removal is accurate. You would just need to jack support the pieces as you remove them and have an extra jack support for the back of the engine because once the transmission support plate (skid plate) is undone, that whole unit is going to be way off center and could potentially mess up your engine mounts.

[@juliusfonferek]

2:13 What are those 2 tubes sticking out above the driveshaft yoke?

[@coolguy_CJ7]

Those are called the slide rail thimbles. They are there to give the shift rails more real estate to move in and out of 2wd and 4wd. I talk about this in the rebuild video

[@juliusfonferek]

@@coolguy_CJ7 I was just curious, thanks for your reply!

[@rajrayasam7357]

Hello, I’m trying to rebuild my 1979 jeep cj5 and I can’t figure out what transmission I have in mine but it looks identical to yours, do you know what transmission that is?

[@coolguy_CJ7]

Send me a couple picts to [e-mail]. Mine is a T150 (3 speed) the only other option pre 80 was the 4 speed T18.

[@jimfesta8981]

I have a T150 in mine. All the manuals show the fill hole on the passenger's side; however, some were made with the fill hole on the driver's side because of the difficult access on the passenger's side.

[@TheGilbertsonfamily]

I have an oddball I'm dealing with right now. It is a 80 CJ7 304 built in 79. It has a Dana 300 (i am absolutely sure of this) but it looks like it is bolted to the Transmission using an adapter that mimics the "Texas" Dana 20 bolt pattern. I'm not sure what Transmission it is. It is a 4 speed and first gear is pretty low. It is either a T18 or T176. My Guess is that it is a T18 because of the Texas bolt pattern. It is not the circular 6 or 5 bolt pattern of the T4 from my 82. Weird stuff. Lots of parts bin Tech, or aftermarket parts by a previous owner.

[@TheGilbertsonfamily]

I crawled under there. It is a T176 with the same type of tailhousing adapter I mentioned. So I answered my own comment. 304, T176, Dana 300

[@coolguy_CJ7]

@@TheGilbertsonfamily Interesting combination. Did a little more research. Apparently the Dana 20 ended in 79 as did the t150 and t18. But the 304 was used till 81. So your combination may be original. But who am i to say otherwise. 😁

[@davidwalker2781]

Where is the Fill Plug? and how much & type of oil do I replace back into the Dana20?

[@coolguy_CJ7]

I used the same for the T150 and the transfer case. 80-90 gear oil. Went with Lucas oil. Yes it's more than what the T150 needs but it makes me feel better :) IIRC it was about 4 quarts for the transfer case. The fill plug is to the top right if youre looking at the back end of the Dana 20 it's a square shaped bolt head, about 1/2" across.

[@davidwalker2781]

@@coolguy_CJ7 awesome. Thank You. I look forward to draining and replacing the gear oil in my T18 next. By the way, (i read several places) that the Dana20 transfer case only takes about 3 Pints - which equals a little Less Than 2 quarts. And, yes, as i filled it up, at about 1 1/2 quarts of new gear oil.... it was at (about) to spill over and out of the Fill plug hole.

[@coolguy_CJ7]

Good information for everyone reading this. Fill it till it spills out. :)

[@andyanajones3808]

Sweet video! I will be removing my D20 sometime soon. Thanks for the tips. Always trust a guy who wears flip-flops when wrenching in his garage.hahhahaha Just kidding.

[@coolguy_CJ7]

Probably not the best choice in apparel, but the way that I look at it, unless I've got steel toed boots on, not much will help dropping a D20 on your foot.

[@monz78]

Those two gears on the back of the transmission go with the transfer case. You take the nut off you should have a 6 or 10 spline shaft coming out of the transmission.

[@coolguy_CJ7]

Correct. I when I removed this, I didn’t have a ton of information on it. Then I rebuilt it, and learned. May not be completely versed in the terms but I’m getting there.

[@patriotfox7192]

My 73 has a Dana 20 original on it. Or it’s identical to the Dana 20 C18-15-24-5G I looked up the original specs and it is a Dana 20.

[@coolguy_CJ7]

Sounds right. I don't how far back the Dana 20 goes in the CJ history, but if yours is a 73 then I'm willing to bet at least into the late 60s.

[@patriotfox7192]

@@coolguy_CJ7 looks like 1972 to 1980s. The 1971 CJ5 has the Dana 18.