Dana 24 disassembly/ rebuild
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Dana 24 disassembly/ rebuild
Just bought a 72 f250. Someone drove it with bad t-case mounts and beat the bearings out of the input and rear output. Finding mounts, bearings and seals is not a problem, finding disassembly/ rebuild info online.....impossible so far. I have contacted every reputible shop in the U.S. Replacing it with 205 not an option for me for a while and would prefer to keep it original. HELP!
- basketcase0302
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Re: Dana 24 disassembly/ rebuild
Maybe this will help:
And have you tried the Dana library for literature on the 24:
http://www2.dana.com/expertforms/depdf.aspx?prod=AXL
And have you tried the Dana library for literature on the 24:
http://www2.dana.com/expertforms/depdf.aspx?prod=AXL
Jeff
http://www.fordification.com/forum/view ... 22&t=46251
SOLD-71 F-350 dually flatbed, 302 / .030 over V-8 with a "baby"C-6, B & M truckshifter, Dana70/4.11 ratio, intermittent wipers, tilt steering, full LED lighting on the flat bed, and no stereo yet (this way I can hear the rattles to diagnose)! SOLD!
Many Ford bumps / one 76' EB / and several dents through the years.
A lot of "oddball" Ford parts collected from working on them for 34 years now!
2008 Ford Escape 4 x 4
http://www.fordification.com/forum/view ... 22&t=46251
SOLD-71 F-350 dually flatbed, 302 / .030 over V-8 with a "baby"C-6, B & M truckshifter, Dana70/4.11 ratio, intermittent wipers, tilt steering, full LED lighting on the flat bed, and no stereo yet (this way I can hear the rattles to diagnose)! SOLD!
Many Ford bumps / one 76' EB / and several dents through the years.
A lot of "oddball" Ford parts collected from working on them for 34 years now!
2008 Ford Escape 4 x 4
- eggman918
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Re: Dana 24 disassembly/ rebuild
A few years back I rebuilt my 24 with only the above diagram and it went pretty smooth,it is a very straight forward project.the trickiest part for me was keeping the lose needle/roller bearings in place
while assembling the main shaft,I finely ended up putting them in the pocket with grease and putting it in the freezer till it got good and stiff then they stayed put while I lined it up
Use your digital camera take lots of pics for reference and you should be OK. this is the D-24 Dwg.
while assembling the main shaft,I finely ended up putting them in the pocket with grease and putting it in the freezer till it got good and stiff then they stayed put while I lined it up
Use your digital camera take lots of pics for reference and you should be OK. this is the D-24 Dwg.
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Steve
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
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Re: Dana 24 disassembly/ rebuild
Thanks for the response guys. That diagram is the only thing I have been able to source. Where should I start? Do the bearings press off the shaft while still in the case? Which direction? etc. I have been a Samurai guy since the mid nineties. Installed 6.5:1 gears in a sammy case. I'm just a little confused where you can't split this case. Would love to come up with some literature. Thanks again, and this is a great site.
- DisposableAssets
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Re: Dana 24 disassembly/ rebuild
Most of those old Dana cases are very straightforward. Unlike many of the chain driven and viscous clutch style cases today. The above diagram is pretty much all you will need. With the needle bearings I have used "red and tacky" Lucas grease and it holds them in place long enough to install the shaft. I've rebuilt a few Dana 20 cases from a few CJ Jeeps, and they were all fairly easy. I took a ton of pictures, labeled, and bagged everything. A parts washer or loads of brake clean will be your best friend too. Also don't forget to use some kind of grease or oil on the yoke seals during install. That way they slide around the shafts without ripping.
It's all just a bunch of nuts and bolts. Man made it, man can remake it.
- eggman918
- Blue Oval Guru
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Re: Dana 24 disassembly/ rebuild
The bearings are a slip fit in the case and a press fit on the shafts, I think it's only .0003" interference so if you dont have a press they can be installed with a bearing driver and a #3 hammer or you canjlycans wrote:Thanks for the response guys. That diagram is the only thing I have been able to source. Where should I start? Do the bearings press off the shaft while still in the case? Which direction? etc. I have been a Samurai guy since the mid nineties. Installed 6.5:1 gears in a sammy case. I'm just a little confused where you can't split this case. Would love to come up with some literature. Thanks again, and this is a great site.
heat them in a small pot of clean motor oil heated to 325-350 degrees we used an old deep fryer for that job in the last shop I worked at.
Steve
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
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- Joined: Mon Jan 14, 2013 2:10 pm
- Location: Radnor, WV
Re: Dana 24 disassembly/ rebuild
Good deal. I guess just take the set screw/bolt from the shift collar and slide it into the case and hit the shaft with a dead blow will work? Next question is about the 50W recomendation. Is it absolutely necessary or will 75-90 be okay? Sorry about so many ?'s, not trying to wear you out. Just anxious to get this thing going. Had a 71 about 10 years ago and have kicked myself for getting rid of it. Very hard to find around here (SW West Virginia)
- basketcase0302
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Re: Dana 24 disassembly/ rebuild
I ran 75-90 in the 24 of my old early Bronco for over 20 years with no issues, (South Florida though). But maybe get a little more input on the difference in the temps up here-versus running the lighter weight.
Jeff
http://www.fordification.com/forum/view ... 22&t=46251
SOLD-71 F-350 dually flatbed, 302 / .030 over V-8 with a "baby"C-6, B & M truckshifter, Dana70/4.11 ratio, intermittent wipers, tilt steering, full LED lighting on the flat bed, and no stereo yet (this way I can hear the rattles to diagnose)! SOLD!
Many Ford bumps / one 76' EB / and several dents through the years.
A lot of "oddball" Ford parts collected from working on them for 34 years now!
2008 Ford Escape 4 x 4
http://www.fordification.com/forum/view ... 22&t=46251
SOLD-71 F-350 dually flatbed, 302 / .030 over V-8 with a "baby"C-6, B & M truckshifter, Dana70/4.11 ratio, intermittent wipers, tilt steering, full LED lighting on the flat bed, and no stereo yet (this way I can hear the rattles to diagnose)! SOLD!
Many Ford bumps / one 76' EB / and several dents through the years.
A lot of "oddball" Ford parts collected from working on them for 34 years now!
2008 Ford Escape 4 x 4
- eggman918
- Blue Oval Guru
- Posts: 1098
- Joined: Fri Nov 20, 2009 12:56 pm
- Location: Paulden,AZ.
Re: Dana 24 disassembly/ rebuild
From '91 till I overhauled it in 08 ran 75-90,now I am running 75-90 synthetic so far so good,the synthetic is about the same thickness as 50 wt
Steve
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
The"Filthy Beast"- '68 F-250 Crew Cab 131"W/B 4x4 4BT compounds hx30/Wh1c,5x.012" sac injectors/ZF 5/NP203-205 /3.54 44 trutrack front/60 trutrack rear on 33's. 2nd owner
"Beauty is only skin deep....Ugly is to the bone"
It is more important to understand what you don't know than what you do know,because then you can start to learn..???
"you must deal with the attaboys and the ass chewing s with your head up and looking them in the eyes" T.J.E. aka My Dad
There are only three types of people wolves, sheepdogs, and sheep. What are you?
- averagef250
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Re: Dana 24 disassembly/ rebuild
Most of the D23/24 cases I've rebuilt have had damaged pocket bearings a long with the input bearings being pretty hammered/sloppy. The pocket bearing must starve for lube in these old things. Opened up a bunch of these old cases to find the pocket bearing has been machined out for a bronze bushing. I rebuilt the 24 in my '70 a couple times in a little over a year (lot of miles though). I just used off the shelf kits and ran low grade 90wt. `I swear I could tow a 10K pound trailer 500 miles and destroy the bearings in a 24. I went to a 205, no more issues.
I have rebuilt a few D23's and 24's since then and I have switched to buying just the gasket kit and using all Koyo or better sealed bearings instead of the original open faced and running synthetic lube.
The sealed bearings never starve for lube and only rely on the oil for cooling. Most modern transmissions and transfercases also use sealed bearings in applications like this and it greatly increases the life and power handling abilities.
All the bearings in a 24 are off the shelf metric bearings.
I have rebuilt a few D23's and 24's since then and I have switched to buying just the gasket kit and using all Koyo or better sealed bearings instead of the original open faced and running synthetic lube.
The sealed bearings never starve for lube and only rely on the oil for cooling. Most modern transmissions and transfercases also use sealed bearings in applications like this and it greatly increases the life and power handling abilities.
All the bearings in a 24 are off the shelf metric bearings.
1970 F-250 4x4 original Willock swivel frame chassis '93 5.9 Cummins/Getrag/NP205/HP60/D70