I will be replacing the rear yoke on my Dana 20 with a flange. Is there anything else I will need to do besides torque to 125 ft lbs ?

No.

Check that the seal is good. Might be cheap insurance to replace.

Excellent.. what about the Rear axle? I guess to be safe I will need to pull the third member and setup with a crush sleeve.. I hear some of you have been able to swap a Yoke right on the axle however.. how was this accomplished?

ok will do.. forgot about the pinon support..

You may need a new gasket at the pinion support as well, or some good RTV.

Ahh yes, must have been thinking of those shims.

I'd not use a crush sleeve. Find a shim able sleeve and replace the crush sleeve. Under high torque loads the crush sleeves are know to continue to crush on there own(been there).

http://broncograveyard.com/bronco/i-222 ... r-kit.html

I might have a new crush sleeve too if you still want to go that route. I just have to check my many boxes of axle parts.

i know i have a few new crush sleeves.. i will try the pre-load route and go from there, let you know how it goes :)

Pulled the rear Yoke off the Dana20 and installed the flange however i noticed the seal isn't sealing around the yoke. The yoke is very very slightly smaller, enough you can tell the seal probably isn't quite touching the flange. Do you think replacing the seal will solve that? I did order the correct flange, or so I believe as they asked me if i had a large or small seal.. maybe I have the large seal? Will I be able to pick one up locally or do I have to order?

Can you measure them? The seals have pretty tight tolerances on the inner size.

sure I will break out the calipers tomorrow and see what the difference is.. i have a feeling they might have goofed on the Flange... but we will see

Here are the seal dimensions.

Seal Outside Diameter (in): 2.508
Seal Shaft Size (in): 1.563
Seal Width (in): 0.311

ok thanks. i will measure tonight to determine whats going on