Dana 20 Transfer Case Parts for Jeep CJ7
Gears, bearings, oil seals and gasket kits for a complete overhaul (1976-1979).
Why the Dana 20 in your CJ7 eventually asks for attention.
The Dana 20 is the transfer case of the early CJ7 years: a fully gear-driven cast iron unit that splits torque from the transmission to the front and rear axles. Its best-known weak spot sits right in the middle – the intermediate shaft runs on two rows of loose needles working without a cage between shaft and gear. Once those needles migrate or the thrust washers wear thin, radial play develops, showing up as a hum and a knocking noise under load while permanently damaging the gear teeth. At the same time the input and output seals and the shift rod seal age: after decades the compound hardens, gear oil escapes at the yoke and shift tower, the oil level drops unnoticed and wear accelerates. Anyone opening a Dana 20 is therefore well advised to renew bearings, gaskets and wear parts in one go.
What you need for the overhaul
- Complete repair and gasket kits: For a full rebuild the Dana 20 overhaul master kit bundles bearings, gaskets and seals; for smaller jobs the gasket and oil seal kit is usually enough.
- Intermediate shaft and needle bearings: Cure the classic wear point with the intermediate gear shaft kit including 48 needles, spacers and thrust washers; individual needle rollers as well as spacers and thrust washers are available separately.
- Gears: When the tooth flanks are worn, replace the intermediate gear or the main shaft gear; the front output shaft gear is stocked as well.
- Bearings, cups and shims: For the rear output you will find the output shaft bearing and cup along with the matching bearing shim kit for setting the correct preload; the front output shaft bearing is ready to ship too.
- Gaskets and oil seals: The housing gasket for Dana 18/20/300 and the gasket to the T18, T98 or T150 transmission seal the joint faces; the intermediate shaft seal plus the output and shift rod seals stop the oil loss to the outside.
- Shift linkage and driveline connection: Against cracked rubber parts the shifter boot is the answer, joined by poppet ball, poppet spring and shift rod cap; on the output side the propeller shaft yoke for Dana 30 and Dana 44 connects the case to the shaft – pinion nut and lock washer included.
Crown, Dana Spicer and Daystar in this category.
By far the largest share of this category comes from Crown Automotive, the US specialist that has kept classic CJ models supplied for decades – from a single needle roller to the complete overhaul kit. Pinion nut and lock washer come from Dana Spicer, original equipment manufacturer of the case itself, while the polyurethane transmission mounts are made by Daystar. Three American manufacturers whose dimensional accuracy makes the difference when a Dana 20 goes back together.
Questions about shims and assembly sequence?
With the Dana 20 in particular, details decide the outcome: the correct output shaft preload, the order of thrust washers and spacers on the intermediate shaft, the right torque figures. Talk to us before you close the housing – we are happy to advise on compatibility and installation. Your order leaves the warehouse in Germany as quickly as possible once payment clears.