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Old 02-23-2014, 04:55 PM   #1
Scout Hokie
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Default Transfer Case - Only have 4L (Dana 20)

Need some advice, I've got a '74 Scout II with 345 / 727 / Dana 20 single stick transfer case. The po never mentioned having any issues with the transfer case but I know he did take the trans. Out to rebuild it so not sure what, if anything, he did to the transfer case. I just can't get the sucker into anything other than 4 low. I've put it in 4l and moved a few feet up and back in the driveway just trying to see if something will free up but no joy. It will shift to neutral and then trying to pull it back any farther back than that is just impossible. Any recommended course of action? I don't think he used rtv between the transfer case and trans. But I also can't tell if he used the proper gasket either. Is that something that could cause this? I've got a donor '74 Scout with a manual trans and good transfer case that I'm going to swap over but was hoping to enjoy this truck for a few months first since I've already been working out other issues over the past 4-5 months. Thanks as always for the help!
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Old 02-24-2014, 04:32 AM   #2
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Default Re: Transfer Case - Only have 4L (Dana 20)

The d20 t-case in combination with a 727 auto can be fussy to shift at times. Just something about that combo that doesn't present itself in a d20/manual trans combo. Have you tried getting it to 2hi with the engine stopped? Sometimes the running engine will actually place a bind on the t-case even with the trans in neutral and shutting off the engine will relieve that bind.
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Old 02-24-2014, 04:43 AM   #3
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Default Re: Transfer Case - Only have 4L (Dana 20)

Yea unfortunately I sure have, I've tried it with the motor off. I've also tried shifting the transmission to neutral and then while shifting the transmission back to park, also attempting to shift the transfer case, all to no avail, it just will not budge past neutral. The one thing I have not done is check the fluid level in the transfer case. That'll be on my list to do tonight.
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Old 02-24-2014, 04:16 PM   #4
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Default Re: Transfer Case - Only have 4L (Dana 20)

Well fluid level is ok in the transfer case and upon closer examination, the po did use what appears to be the proper gasket between the trans. And transfer case. Looks like he May have smeared it with some of the indian head permatex stuff.

Any ideas what could be going on??
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Old 02-24-2014, 04:23 PM   #5
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Default Re: Transfer Case - Only have 4L (Dana 20)

Does the Scout have a body lift? If it does chances are the shifter is hitting the floor and thus preventing it from being shifted into 2hi or 4hi.
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Old 02-24-2014, 05:05 PM   #6
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Default Re: Transfer Case - Only have 4L (Dana 20)

Nope, no body lift on this Scout. It was very nearly an unmolested Scout other than the po ripping off most of the smog equipment. I am completely befuddled. When underneath the truck, I don't see any issues with the lever binding or catching on anything.
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Old 02-25-2014, 08:16 AM   #7
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Default Re: Transfer Case - Only have 4L (Dana 20)

So the transfer case will only go into 4low and neutral but not 2hi or 4hi, correct?
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Old 02-25-2014, 09:55 AM   #8
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Default Re: Transfer Case - Only have 4L (Dana 20)

Jeff,
yea, thats correct. Goes into and out of 4 low nearly effortlessly, no problems at all. I've got that spare Dana 20 and I think I May just bite the bullet and swap them out over the weekend. Then I can get this 'bad' transfer case out and inspect it. Not the worst thing in the world to swap out.
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Old 02-25-2014, 10:46 AM   #9
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Default Re: Transfer Case - Only have 4L (Dana 20)

When you take out the fautly unit make sure it has a Dana 20 bull gear on the back of the transmission and not a Dana 300 one. The inner toothed gear portion on the gear is what engages 2hi. The Dana 300 is bigger and would not allow 2hi engagement. Pictures of both are shown for reference.

Dana 300


Dana 20
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Old 02-25-2014, 12:43 PM   #10
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Default Re: Transfer Case - Only have 4L (Dana 20)

Ah ha, great recommendation. I'll do that and post my findings probably later this weekend. Thanks for the info.
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Old 02-25-2014, 01:06 PM   #11
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Default Re: Transfer Case - Only have 4L (Dana 20)

Oh Jeff, one question. Based on your comments, I half expect to discover a Dana 300 bull gear. I do have a Dana 20 bull gear on the manual trans. That I pulled from my donor so if I do discover a Dana 300, I should be able to just swap it with my Dana 20 bull gear, correct? Just making sure. Thanks again.
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Old 02-25-2014, 01:40 PM   #12
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Default Re: Transfer Case - Only have 4L (Dana 20)

No. The man bull gear is for man's. You'd need a d20 auto bull gear.
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Old 02-25-2014, 05:25 PM   #13
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Default Re: Transfer Case - Only have 4L (Dana 20)

Ah thats right, the manual has the 6 spline interface. Welp, I guess if that is the issue then I'll be deciding whether or not to buy a bull gear or go ahead and tackle the full transmission swap haha. Guess we'll see if thats the problem.
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Old 03-02-2014, 08:50 AM   #14
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Default Re: Transfer Case - Only have 4L (Dana 20)

Ok brain trust, got the transfer case off this morning. Verified that the bull gear appears to be correct to the Dana 20. So I started playing with it out of the car and shifting through the positions. It still does not want to go into 2h. I've taken several pictures, hopefully the titles come through because that helps keep them straight. 'trans_bull_gear' is a shot of the bull gear. 'bad_4l' is the bad transfer case in the 4l shifter position. 'bad_neutral_pos' is the innards in what felt like the shifter neutral position but almost appears like its nearly 2h. 'bad_shifter_neutral' is a shot of the shifter and shift rod positions at the 'neutral' position. Ok so then for comparison, I took pictures of the other Dana 20 that I have that seems to shift well. Titles are a bit self explanatory but 'good_4l' is the good transfer case in the 4l shifter position. 'good_2h' is the good transfer case in the 2h shifter position and 'good_shifter_2h' is the good transfer case shifter and shift rods in the 2h position.

What do you guys think? Feel free to fire more questions if you need me to take more pictures, etc. Thanks!
Attached Images
File Type: jpg Trans_Bull_gear.jpg (46.7 KB, 259 views)
File Type: jpg Bad_4L.jpg (60.8 KB, 303 views)
File Type: jpg Bad_Neutral_Pos.jpg (52.2 KB, 296 views)
File Type: jpg Bad_Shifter_Neutral.jpg (52.6 KB, 257 views)
File Type: jpg Good_4L.jpg (52.8 KB, 203 views)
File Type: jpg Good_2H.jpg (64.4 KB, 337 views)
File Type: jpg Good_Shifter_2H.jpg (55.6 KB, 237 views)
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Old 03-02-2014, 09:05 AM   #15
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Default Re: Transfer Case - Only have 4L (Dana 20)

That "bad" transfer case appears to be shifting into 2hi just like your "good" one.
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