SVO42's BW1354/Dana 20 doubler build

SVO42 · 09-05-2009, 07:53 PM

I'm just getting started with this. It's also tied to my SAS (http://www.explorerforum.com/forums/...d.php?t=237798). I plan on cutting up my existing manual shift BW1354 to be the low range box. I scored a good deal on a Ford 3-speed and "T-shift" Dana 20 from an early Bronco. The T-shift has the more desirable 2.46 low range. In low-low I'll have a ratio of 6.1:1.

This stuff was/is still filthy! Almost 40 years of gear oil-based mud and muck:

The inside of the case looks good, though!

Here's the 3-speed. I'll be pulling the shaft and gear to go on my eventual spud shaft.

More to come!

lifeguard379 · 09-05-2009, 09:43 PM

SVO42 · 09-06-2009, 05:10 PM

Got the adapter separated from the transmission today. You can see how it's set up from the following pictures. The 3-speed's output shaft slides into the adapter housing's shaft female end. This part is 28 spline. Once I have the adapter housing shaft out I'll be able to make a better determination of the best way to go about making the doubler shaft.

3-speed with adapter housing off:

Looking into the adapter housing from the transmission side:

Adapter housing next to the Dana 20. You can see the gear on the end that drives the gears in the D20 (where the sock/rag is right now):

I'll be stopping here until I can get the parts over to my friend Neil's house who's helping me with this and my axle swap. He's got the shop and the press I'll need to get the shaft and gears out of the adapter housing.

Explorer_Phil · 09-06-2009, 07:54 PM

redranger4.0 · 10-01-2009, 06:41 AM

any progress?

SVO42 · 10-02-2009, 09:19 PM

Unfortunately, no. My wife's horse foundered two weeks ago. He'll probably be OK, but he's not at our house. Instead, he's 45 miles away and has needed twice daily care. We were planning on getting our place horse-ready this spring, but we really need to have him at our place ASAP. Because of that, we've been devoting all of our time and money toward building a fence/corral and modifying our barn.

I hope to start making some progress in a month or so. I have a wedding this weekend and another one the weekend after! It'll get done, don't worry. Once I have ade some progress I'll post up.

09-05-2009, 07:53 PM	#1
SVO42 Wannabe Elite Explorer Hatton, MO 1994 XL Join Date: Dec 2002 Posts: 455 Vehicle Specs (Original Poster)	SVO42's BW1354/Dana 20 doubler build I'm just getting started with this. It's also tied to my SAS (http://www.explorerforum.com/forums/...d.php?t=237798). I plan on cutting up my existing manual shift BW1354 to be the low range box. I scored a good deal on a Ford 3-speed and "T-shift" Dana 20 from an early Bronco. The T-shift has the more desirable 2.46 low range. In low-low I'll have a ratio of 6.1:1. This stuff was/is still filthy! Almost 40 years of gear oil-based mud and muck: The inside of the case looks good, though! Here's the 3-speed. I'll be pulling the shaft and gear to go on my eventual spud shaft. More to come! __________________ Dana 60/Sterling 10.25" build status: SAS complete! Now working the bugs out. SAS: SVO42's 1-ton SAS

09-05-2009, 09:43 PM	#2
lifeguard379 Wannabe Elite Explorer sacremento,ca 93 eddie bauer 2 door Join Date: Jul 2004 Posts: 1,211 Vehicle Specs	__________________ 93 2 door eddy Bauer HP44 and Big bearing 9 and 4.88 My elite registry http://www.explorerforum.com/forums/...d.php?t=153392 sas thread http://www.explorerforum.com/forums/...d.php?t=165147 sas registry http://www.explorerforum.com/forums/...d.php?t=244780

09-06-2009, 07:54 PM	#4
Explorer_Phil Wannabe Elite Explorer Clarksville, TN '01 Sport Join Date: Mar 2008 Posts: 59 Vehicle Specs	Subscribe __________________ 2001 Ford Explorer Sport; Help Me Upgrade It! Done: TT, Shackles, 4-Door Leaf Springs, 31x10.5 BFG AT K/O Short Range: FIX RUST(Done), Electric to Manual T-Case Mod (Fixed E-Motor), Body Lift Long Range: 4.56, Rear Locker, 33's

10-01-2009, 06:41 AM	#5
redranger4.0 Wannabe Elite Explorer Salem CT 2000 Ranger XLT Join Date: Apr 2003 Posts: 738 Vehicle Specs	any progress? __________________ Join the Resistance

09-06-2009, 05:10 PM	#3
SVO42 Wannabe Elite Explorer Hatton, MO 1994 XL Join Date: Dec 2002 Posts: 455 Vehicle Specs (Original Poster)	Got the adapter separated from the transmission today. You can see how it's set up from the following pictures. The 3-speed's output shaft slides into the adapter housing's shaft female end. This part is 28 spline. Once I have the adapter housing shaft out I'll be able to make a better determination of the best way to go about making the doubler shaft. 3-speed with adapter housing off: Looking into the adapter housing from the transmission side: Adapter housing next to the Dana 20. You can see the gear on the end that drives the gears in the D20 (where the sock/rag is right now): I'll be stopping here until I can get the parts over to my friend Neil's house who's helping me with this and my axle swap. He's got the shop and the press I'll need to get the shaft and gears out of the adapter housing.

10-02-2009, 09:19 PM	#6
SVO42 Wannabe Elite Explorer Hatton, MO 1994 XL Join Date: Dec 2002 Posts: 455 Vehicle Specs (Original Poster)	Unfortunately, no. My wife's horse foundered two weeks ago. He'll probably be OK, but he's not at our house. Instead, he's 45 miles away and has needed twice daily care. We were planning on getting our place horse-ready this spring, but we really need to have him at our place ASAP. Because of that, we've been devoting all of our time and money toward building a fence/corral and modifying our barn. I hope to start making some progress in a month or so. I have a wedding this weekend and another one the weekend after! It'll get done, don't worry. Once I have ade some progress I'll post up.