The T-18A when purchased came with a Dana 20 with the 2:1 low range.
I looked into swapping the Dana 20 for a Dana 300 but discovered that
the require adapter cost more than a low range kit for the Dana 20.
The Jeep Dana 300, which would bolt up to the T-18 are hard to find so I
opted to stick with the existing Dana 20 that I could either swap the
gears for a kit or do a Spicer 18 gear set/Bronco input gear swap that
would give me a 2.46:1 ratio so I'm looking for parts for that.
The condition of the Dana 20 was pretty good when I inspected it
internally so an overhaul wasn't necessary. I did want to update
some of the seals before bolting it into the CJ-7 so I purchased a Dana
20 seal kit which included a much needed seal for the Dana 20 to the
adapter. Replacing the seals was relatively easy because I only
replaced the easy to access seals. The main reason I didn't
replace all the seals was because I may eventually look into swapping
gears from a Ford Dana 20 which has lower low range gears that the Jeep
Dana 20 and supposedly it's possible to just swap the gears. If I
ever do that I may end up changing the seals again anyway. Also I
needed to shorted the shifter linkage because the T-18A/Dana 20 came out
of a J-20 and the Dana 20's shifter was more forward than the T-18A's
shift and would put it well under the dash of the CJ-7.
The output shaft seals were removed after removing the yokes and
the new seals were pressed in using the throwout bearing of the old clutch which
fit nicely over the seal's outer edge. I used a hammer to gently tap the
seal into place.
Seal is pressed in and ready for the yoke.
Next up was the small seals around the shifting rods.
Again I removed them with a small regular screw driver and this time I pressed
them in with a deep socket.
Next I removed the bottom plate again and cleaned out any debris that may have
gotten in to the case and cleaned the cover plate.
To the right is the seal that goes between the adapter and the
T-18A. Both surfaces were cleaned and coated with the blue stuff, the seal
stuck in place and then the Dana 20 was bolted to the adapter.
Below are some shots of shortening the shifting linkage for the Dana 20. I
actually did some of this before bolting the Dana 20 to the adapter. It
was tough getting the shifter housing off of the tub but a little heat applied
to the tube and a pipe wrench on the shifter housing and it came off. I
wouldn't recommend applying force to the shifter itself to twist the housing
off. Instead put a pipe wrench on the cast housing to twist it off.
First
thing was to figure out where I wanted to put the shifter relative to the
T-18A's shifter. I ended up rounding off the shorted amount to 3 inches
(easier math) and cut that much off the tube that braces shifter to the Dana
20. Then I drilled out the new holes in the tube by slipping on the
shifter housing and lining it up as straight as possible again and marking the
spots where to drill and removing the housing again. Then I drilled the
tube out using the size drill bit as it was before (old holes). I didn't
drill it out all the way though. My thinking was that the way the bolt
ends were shaped it would be better to allow the end of the set bolt to sink
into the tube and make it's own hole as to assure a tight fit. It was at
this point that I replaced the seals in the Dana 20 and bolted it up to the
adapter.
Next up was to shorten the linkage rods. I've seen some
people cut and weld these rods (as well as the connecting pipe) but I chose to
cut, reshape and drill out the male end of the linkage with an angle
grinder. It wasn't that difficult. I just took my time and measured
everything many times over to be sure I was right on.
Here's a comparison of an old set and the new shortened set of
linkage.
Shifter housing, ready to go on. I had cleaned and
inspected it prior to this point.
Test fit. I also ran though the gears to make sure everything was right.
Once the Dana 20 was bolted up it was just a matter of bolting the housing on
and attaching the linkage.
Last I filled the Dana
20 with gear oil and filling the shifter housing with grease.
Gear Shift
When the Tub was lowered onto the frame, the Dana 20 stick shift
off of a J-20 Pickup didn't quite line up with the Jeep's stock opening.
Three options: Cut the opening, modify the stick shift, or find a new shift
linkage. I kind of like the throw of this linkage (plus money is always an
issue) so I decided to modify the stick shift. So, I cut two stick
shifts up and welded an offset piece 3/8" steel to each half as picture to
the right. Worked like a charm.
Cover plate (see below)
To the right you can see the reason for the
offset.
With a custom gear shift, come a custom cover plate. I needed to
fabricate a cover plate out of something. After looking around a little, I
found some sheet metal of an old PC case that was ready for the scrap
heap. The sheet metal was thin enough to cut with shears and strong enough
to use for this application. A template was cut out of cardboard and then
transferred to the sheet metal. After a paint job and a couple of boots
it'll do the trick.
This design took a little bit of work but I ended up with a
pretty cool looking cover plate. The boot on the T-18A is off the shelf
from an auto store and the Dana 20 cover plate is a custom fab job using the
pieces of the computer case and an old rubber inner tube. I'm going to do
an inverted boot on the Dana 20's shifter.