Garage-Build Trans­fer Case

Dana 18 re­build you can do

Jp Magazine - - TABLE OF CONTENTS - By Brian Gabriel jped­i­tor@jp­magazine.com Pho­tog­ra­phy: Brian Gabriel

The Dana 18 trans­fer case was in place be­hind the trans­mis­sions of Jeeps be­gin­ning in 1940

and last­ing un­til 1971. Dif­fer­ent ver­sions of the Dana 18 have seen the grunt of the bat­tle­field, worked around the farm, and cruised the town in the first lux­ury Jeep—the CJ-5A Tuxedo Park. This old-school trans­fer case is a gear-driven de­sign that is stuffed in­side of a cast-iron case. The Dana 18 also had the aux­il­iary op­tions avail­able like an over­drive unit; power take-off (PTO) unit that can be used to run im­ple­ments such as a winch, trencher, welder, belt drive drum; and just about any­thing you can think of. Check out our “Dana Spicer 18— The Best Trans­fer Case Ever?” ar­ti­cle (four­wheeler.com/how-to/trans­fer­case-dana-spicer-18) for more rea­sons why this ven­er­a­ble trans­fer case should be re­built in­stead of going on the scrap pile.

While these trans­fer cases are gear driven, tough, and durable, some could be nearly 80 years old, and the wear­able in­ter­nal parts have seen much bet­ter days. They are also known to leak oil from time to time, and that leads to ad­vanced wear if ne­glected (fluid level not checked reg­u­larly). If your trans­fer case is pop­ping out of gear or has ex­ces­sive end­play on the out­put shafts, then it is time for a re­build. No mat­ter which ver­sion of the Dana 18 you have, all of the parts are avail­able to get it back into work­ing or­der. We show you the ma­jor steps to re­build the Dana 18, along with a few tricks in the name of con­tin­u­ous im­prove­ments.

At this point in our Dana 18 trans­fer case re­build its guts had been dis­as­sem­bled and made clean again, and its case was freshly painted. We did all this while the in­ter­me­di­ate gear was off to Herm the Over­drive Guy for ma­chine work.

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