This is my first attempt at a Dana 20 rebuild and I have been following this manual ( http://www.classicbroncos.com/dana20/da ... anual.html ) and a few questions to Viper to guide me. I am now stuck at the removal of the front output shaft. I have removed the bearing cup from the case bore (Disassembly step 15) and now stuck at step 16. Can someone please clarify how I "wedge the front output shaft front bearing away..." because I cannot get the bearing to budge. Also, with respect to the editor's note following that step, I need to move that bearing to see if there is in fact a snap ring, right?

Christian,

Your tcase may not have a snap ring. It went away somewhere between serial numbers 1699356 and 1729758. When that happened the bearings were changed to a press fit. The old style bearing just floated on the shaft. The old style bearing is easily separated from the snap ring once the shaft is tapped back a little. The J style (pressed) bearing is tight and will need to have the shaft tapped out through it.

If it's a J style tcase it will not have a snap ring. T style might if it falls into that serial number range.