Dana 20 woes

[nothingfancy68]

I'm finishing up with a modification job on a 68. I've upgraded from l-6 to 302, 3 speed on the column to nv3550. I had a local guy at a transmission shop rebuild the Dana 20. (It had been many years since he'd seen one.) He gave me a small bag of roller bearings when I went and picked up the Dana. I don't remember the exact number I used when installing the input shaft. (Now I know there's supposed to be 13) I do remember I could not get all of the rollers in. I used grease to hold them, pushed them together as close as I could. When I got to the end there was a gap about 3/4 the size of one roller. The tolerance with the shaft was close. It took about 20 trys to get it in without knocking over a roller. NOW HERE'S MY ISSUE... I hear a noise when the load is off of the drivetrain (coasting). While sitting in the drivway I can put the tranny in gear and the Dana 20 in neutral and I hear a slight whiring sound (normal?). If I'm driving and let off on the gas I hear a slight grinding sound. (Is there "slight" grinding?) It also makes the noise for a second when I push the clutch.

1) Is this gap in the roller bearings normal? Might the guy have ordered the wrong Dana kit?

2) The guy who rebuilt it says these old t-cases make alot of noise, it's normal. What can you tell me?

3) Could the grinding sound have anything to do with my previous question posting about the twin-sticks?

4) It's also leaking , he said they all do that?

Help, thanks!

 

[STLKIKN]

In two wheel drive the case should be really quiet.

In 4 hi there will be some noise, in 4 low, there will be even more noise.

None of the noises should be able to be described as "grinding" noises!

The clutch should not affect at all any sound coming from the t/case, it would only affect transmission input noises.

1) a very small gap would/ could be considered normal, yes he may have.

2) as mentioned, SOME noise is normal, not "alot"

3) only if the shifters are not adjusted properly.

4) NO, my 8 and 15 year old rebuilds still don't leak.

ps how do you like the 3550?? I am just finishing up gathering all the little odds and ends to do two conversons....

 

[nothingfancy68]

Thanks again! the NV3550 is great so far. The owner of the truck asked me not to put a tach in (nothing fancy) so I can't give you any info on crusing RPM. I can put one in temporarily if you have any questions. I have not driven it enough to check the gas mileage. I'll let you know. I do suggest at least a one inch body lift. I think a vent cap on top on the NV3550 is real close to the body. You may need to rework your twin-stick brackets. Cutting out an access panel on the floor would have made things easier. Here's a link Twin stick bracket NV3550 I have been doing a lot of whining about problems lately. Sorry. Working on this Bronco has been a blast! I may need to start looking for one!

 

[STLKIKN]

Hmmm shiny pic!!

Gotta love it when they still look like that!

As a guess, if you are running 3.50/ 3.54 gears and 33" tires, I predict you will be running ~2000 rpm at 60-65 mph.

Sounds like you may have caught the "bug"!!