from a conversation I had with a fellow from Tera,
please feel free to confirm, deny, or offer ideas/soloutions to the below comments:
>From: xxxxxxxxx - Tera Manufacturing Inc. [mailto:xxxxx@teraflx.com]
>Sent: Tuesday, April 02, 2002 9:33 AM
>To: Richard Schaefer
>Subject: RE: Teralow Lowrange Gears for the Dana 20
>
>
>Thank you for the email, I did some research to see what we
could do. I
>found out the reason we can't is because the bronco case is
quite a bit
>larger than the jeep case. That's why they can fit that big
of a gear. If we
>made it the gears would not fit in the jeep Dana 20 case. I
am sorry I can't
>help you out with that. We would have to specifically make that
gear and to
>change out tooling to do so would be far to expensive. I hope
this helps you
>out.
>
>xxxxxxxxxxx
>Customer Service/Technical Support
>TERA MANUFACTURING
>801-256-9897
>801-256-9879(fax)
>
>-----Original Message-----
>From: Richard Schaefer [mailto:RSchaefer@HNTB.com]
>Sent: Friday, March 29, 2002 8:08 AM
>To: 'teraflex@teraflx.com'
>Subject: Teralow Lowrange Gears for the Dana 20
>
>
>Hi,
>I called last week regarding the Teralow gears for the Dana
20.
>as a re-cap:
>I had mentioned that bcbroncos.com had low gears for the dana
20 that were
>4.86:1, and thiss seemed like new information to you.
>
>Since the Bronco gears are $1500, which is insane, I just want
to know if
>you've had a chance to investigate re-designing the Teralow
Dana 20 gear set
>so that it has a low range similar to the Bronco gear set.
I have no idea.
that's what's irritating me.
I can't possitively say that it's not true, but I have problems believing Dana would make 2 'cases so different, and still call them both Dana 20's.
I must be using too much common sense!
Not sure if this helps but we put the terra low kit into my D-20 and we had do some grinding to get the big gear to fit. The d-20 came frmo a 77 Cherokee Chief.
I have no idea.
that's what's irritating me.
I can't possitively say that it's not true, but I have problems believing Dana would make 2 'cases so different, and still call them both Dana 20's.
I must be using too much common sense!
Dana made THREE Dana 20s that more or less share a designation between them.
The Bronco Dana 20 is very different from the Scout/Jeep Dana 20. It's a left-drop, and has a round mounting pattern, and a much more "streamlined" looking case compared to the Scout/Jeep variety.
You can put Bronco gears in a Scout/Jeep Dana 20 if you grind on the case some to make the bigger Bronco gears fit (or Jeep 18 gears) for the 2.46:1 low range.
I don't know if the 4.86 BCBroncos gearset needs grinding on the Bronco 'case.. if it does, then you would DEFINITELY have to grind on the Scout/Jeep 'case, and it may be so excessive that case integrity would be compromised - or breached.
If you wanted, you could always have someone weld more material to the Dana 20 'case...
O'Brien's sells lower than 3.15:1 gears for the Scout/Jeep Dana 20, too. I don't know just how low (at least 3.73) and how much $$$$.
Oh, that third bastard case?
Somewhere around 1972 or so (IIRC) you could find a Dana 20 in a Chevy Blazer..
I've only run into a couple people that had ever seen one..
the BCBroncos.com website advertizes that no machining is required for the 4.86 gears. Still, I'd think that for $1500, it's too close to an Atlas to make this a justifiable thing to try.
thanks for the Blazer trivia, I live for that stuff.
the BCBroncos.com website advertizes that no machining is required for the 4.86 gears. Still, I'd think that for $1500, it's too close to an Atlas to make this a justifiable thing to try.
thanks for the Blazer trivia, I live for that stuff.
BCBroncos is probably selling Jack's gears. There is no way they will fit in a Jeep case. Jack only makes down to 3.6:1 for the Jeep case. He gets the 4.86's into an 18 case, but it requires cutting out part of the case & welding a new peice on for clearance. All his gearsets are in the 15-1800 $$$ range.
his # is (916)773-3278
well the amount of grinding to put bronco gears into jeep dana 20 is very little, and does not harm the case, but you have to mod. one of the shift forks so it will fix around the bronco gear. My self and a friend did this for me. I am running the case now. So far so good. Also you need the out put gear off of the tranny(manual) that the bronco dana 20 came off of. It is different than the one for the jeep dana 20. You can use the one for a dana 18 it is the same.
1500 for 4.86 not me too much, I would rather run dual t-case and have 2.xxxx and 4.xxx or just spend few more $ and get a altas
yes that is true. That is why I am going to run 2 t-case, I got a adp to div. a dana 20 case.
Well If I had 2k to spend on a t-case I would just get a 465 or hell since I am rich I would get a nv4500 :smokin: but I am not so I will not have that
well if you put the gear out of a 18 into a 20 you sill have a 18 but in a stronger case. My friend did this so it would bolt up to a t18 that has a dana 20 behind it
A year or so ago we tried to put bronco 4.86'ers in a jeep case. WOW not even close grind all you want but the places you have to grind just scares the crap out of me. If you get them in you should resupport the case w/ strap steel and good welding skillzzzzz good luck
I know it's off-topic kinda, but it's a Bronco 20 question none the less.
Do you think a smart feller could take the innerds out of a Dana 18 and swap them into a Bronco Dana 20 to make a driver's drop Dana 18? Yes it would require a custom rear axle with driver's offset, but it would be a cool swap into a Wrangler or Bronco because it would in theory allow the use of a Saturn overdrive, which would make the owner of such a vehicle the envy of all his neighbors.
A Jeep/Scout 18/20 case is just to small to fit the 4.86 gears without milling a slot in the top of the case and welding a plate on to cover the gear because it will stick out the top because it is so large. With a Bronco case they a larger so the gears fit in them with little to no work. O'Brians makes 3.6 and 4.1 gears for the Jeep/Scout 18/20. They are 2x the price because they a 10x as good ths the Terra gears. I have gone through 2 sets of Terra gears and will be going with the O'Briain ones if I stay with the 18. One other upgrade you might want to do is the 32 spline output shaft. AA makes them for the Jeep/Scout 20's now.
I spent a great deal of time on the phone discussing options for lower 20 gears. BTW nice guy if you ever have the chance to talk to him do it. He knows his stuff and does material testing for the US Air Force.
Once upon a time, (they're still out there) Jack put some 4.X gears in a 20 case. The single biggest problem is the shift rail modifications make the install questionable.
I know it's off-topic kinda, but it's a Bronco 20 question none the less.
Do you think a smart feller could take the innerds out of a Dana 18 and swap them into a Bronco Dana 20 to make a driver's drop Dana 18? Yes it would require a custom rear axle with driver's offset, but it would be a cool swap into a Wrangler or Bronco because it would in theory allow the use of a Saturn overdrive, which would make the owner of such a vehicle the envy of all his neighbors.
That is a very interesting idea. I think the biggest obstacle would be the front output housing. On the D18 the shift fork for the front output is in the housing. On the D20 the front output housing just has a shaft in it, and FWD is shifted in the main case. I seriously doubt the D18 front output housing would even come close to fitting on the Bronco D20 case, so you'd have to fabricate your own. Don't know about the rear output either, but it sure looks like it would bolt up. The gears are the same, so at least that part would work. Not sure if a Warn OD would fit either, is the bolt pattern the same?
People use Dana 20 cases to build better Dana 18's, so I assume the shift forks will work in the Jeep case, but the Bronco is all Greek to me. If this could be done you may see a decline in flipping 300's, at least I'd run one, with my SM420 and 5.38's I really miss overdrive.
People use Dana 20 cases to build better Dana 18's, so I assume the shift forks will work in the Jeep case, but the Bronco is all Greek to me. If this could be done you may see a decline in flipping 300's, at least I'd run one, with my SM420 and 5.38's I really miss overdrive.
Yes they do. In fact I have done it myself. Part of the conversion is you have to use the D18 front housing to make it work. Now if someone want's to cast up a few front and possibly rear housings, you might have something.
That's how I thought it worked, so all one would need to do is make the Dana 18 front output / shifter housing work with the Bronco case, so, without ever having seen a Bronco case, how different is the front output housing. I wonder a Jeep Dana 20 rear output would bolt to a Bronco 20 rear output? If so it seems the OD would bolt up, but the front output and the retainer on the back of the front output (which would be the rear out put of the driver's 18) would need all the attention to make it work. Maybe it's just a silly idea, since they don't make many adapters for the Bronco case to any decent transmissions.
Well at least Terra is going to replace my gears and they are made by a different manufacture now because of problems so maybe thies will work better. No if I can only get this 32 spline 205 front output and 32 spline 20 out put to work I'll be ready to GET IT! once again.
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