Advance Adapters 50-3020A - Manual (Page 2)

JEEP & SCOUT DANA 20 T/C TAILHOUSING
32 SPLINE OUTPUT WITHOUT YOKE
ADVANCE ADAPTERS INC. P/N: 50-3020A
P.O. Box 247, 4320 Aerotech Center Way New Item: (04/02)
Paso Robles, CA 93447 PAGE 2 OF 4
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 04-24-02
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components
will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we
strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores
.
The Dana 20 H.D. output shaft kit is a very simple kit to install. The transfer case can be left in the vehicle for the installation
of this kit. Driveshaft modifications will be required due to the 1.5" longer output shaft housing. The use of this kit gives
you the advantage of calibrating you speedometer for tire and axle variations.
Remove the (5) fasteners from the stock tailhousing. Remove the tailhousing from the Dana 20 transfer case. The stock
tailhousing used a gasket between it and the transfer case. Make sure the gasket is removed
completely from the transfer case surface. When comparing the old Dana 20 tailhousing to
the new, there are a couple of changes to our tailhousing that you will need to compensate for.
The first is the length of our unit which is 1.5" longer, so driveshaft modifications will be
required. Second, the speedometer drive on our tailhousing is designed around the later model
Jeep tailhousings. This speedometer drive allows you to adjust your speedometer to
compensate for larger tires and axle ratio changes. Third is the breather assembly. The stock
tailhousing has a metal breather mounted to the top of the tailhousing. Our tailhousing is
designed with a brass elbow. Our tailhousing requires a piece of 3/8" fuel hose to be clamped
to the brass elbow and a breather to be installed at the opposite side of the hose. We also
recommend that this hose be long enough to extend up into the engine compartment to avoid
any type of water contamination.
We designed our kit to bolt to the Dana 20 without a gasket. We recommend using a very thin film of RTV blue silicone.
Apply a small dab and smooth it out with your finger. Our tailhousing also requires the use of a stud bolt located at
approximately 8 o'clock on the case. The stud bolt must be installed so that only .600" is protruding from the case. Make
sure the bolt does not go too far into the case and interfere with the Dana 20 gear. Our tailhousing bolt hole that corresponds