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Help me ! T18 – Dana20 + Dana18 = Gear Noise
I have just finished rebuilding my CJ. I replaced AMC20 with offsetted Waggy44 and in order to solve the bad drive shaft angle, we decided to replace Dana20 with Dana18. I found the required “big hole” (4”bore) dana 18 case from an early Kaiser (unused military surplus :grinpimp: ), and an almost unused willys dana18.... I swap all the gears to Kaiser dana18 with the guidance of Novaks’ chart... install a new idler shaft..
http://www.novak-adapt.com/knowledge/transfer_case_gears_grid.htm
From Dana 18;
Intermediate Gear 18-5-7, 34t x 21t
Front Output Gear 18-8-18, 26t
Front Sliding Gear 18-8-17, 39t
From T18, the same gear used in Dana20;
Drive Gear 18-8-46, 26t x 6
Everything worked fine on the ground (as always), all the gears worked perfectly... but when we install it, in high speed 2h, there is a very high gear sound, especially when I release the throttle... Does anybody have an idea? or experience? My concern is in novaks’ chart, it is said that the helix angle of 18-8-46 17.5 degrees and dana18 gears are 20 degrees, can it be the problem…
Other problems I faced ;
- the front bearing shaft cap of dana18 was touching the side wall of T18, so I grind it around 5mm and it is broken during the installation of sticks… need to find a way.
- and front drive shaft needs to be shorten (if you call it a problem…..)

I have just finished rebuilding my CJ. I replaced AMC20 with offsetted Waggy44 and in order to solve the bad drive shaft angle, we decided to replace Dana20 with Dana18. I found the required “big hole” (4”bore) dana 18 case from an early Kaiser (unused military surplus :grinpimp: ), and an almost unused willys dana18.... I swap all the gears to Kaiser dana18 with the guidance of Novaks’ chart... install a new idler shaft..
http://www.novak-adapt.com/knowledge/transfer_case_gears_grid.htm
From Dana 18;
Intermediate Gear 18-5-7, 34t x 21t
Front Output Gear 18-8-18, 26t
Front Sliding Gear 18-8-17, 39t
From T18, the same gear used in Dana20;
Drive Gear 18-8-46, 26t x 6
Everything worked fine on the ground (as always), all the gears worked perfectly... but when we install it, in high speed 2h, there is a very high gear sound, especially when I release the throttle... Does anybody have an idea? or experience? My concern is in novaks’ chart, it is said that the helix angle of 18-8-46 17.5 degrees and dana18 gears are 20 degrees, can it be the problem…
Other problems I faced ;
- the front bearing shaft cap of dana18 was touching the side wall of T18, so I grind it around 5mm and it is broken during the installation of sticks… need to find a way.
- and front drive shaft needs to be shorten (if you call it a problem…..)
