Dana 20 Transfer Case

The rear output shaft on the Dana 20 transfer case is known to wear down and leak at the rear yoke after years of use. To fix this, there are a couple things you need.

1. New Dana 20 yoke seal: https://tomsoffroad.com/parts/66-77-f...
2. New Dana 20 yoke: https://tomsoffroad.com/parts/66-77-f...
3. Dana 20 Speedi-Sleeve: https://amzn.to/39Ffbt0

To fix the leak at the rear yoke:

1:43 - Remove the rear drive shaft
1:47 - Remove the 1 1/8th nut holding on the rear yoke.
1:55 - Use a harmonic balancer puller to remove Yoke
2:09 - Remove Seal (I’m not removing the seal housing, just the seal)
4:10 - Inspect the rear yoke, replace if necessary
4:46 - Or Install Speed-Sleeve if needed
6:01 - Install new Seal
6:43 - Install yoke
7:05 - Tighten down nut to 150 ft pds
- Re attach rear drive shaft

Now I’ll make a disclaimer right here, this would be a great time to upgrade to the HD Rear output shaft from TBP. It’s about $500 and beefs up this output shaft because the have a tendency to break on the trail. I’m not doing that today, we are just fixing leaks, but it is on my list of things to buy and it should be on yours.

HD Rear Output shaft: https://tomsoffroad.com/parts/66-77-f...

There is also a great article on Classic Broncos about where leaks are coming from and how to fix them: https://classicbroncos.com/forums/sho...

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