Join Date: Sep 1999
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Re: Transfer Case (pill Insert)
Here's a paragraph from the writeup. I don't know how to post the link but do a search and put in, Twin stick Pigpgen, Search options = AND, then select all posts. It's from 2001 and there are some pictures.
In order to get the full benefit of this modification the transfercase must be first taken apart to REMOVE THE SHIFT RAIL INTERLOCK PILLS. Failure to do this will make the Twin stick setup useless.
Twin sticks from Dana 18, assorted stock D20 linkage parts, 1/2 inch bolt 4 1/2inch long, lock nut and 1/2 inch nylon washers of various thicknesses, and 1/16 inch flat metal stock.
Tools needed: Drill(Drill Press was also used but it not needed), torch (for heating and bending), sawsall(to cut the metal stock), grinder(to clean up the metal stock), driLl bits, hammer, tape measure, etc.
I removed all the old Dana 20 linkage and then heated up and bent the u bracket on the pipe to gain more clearance for the first stick to be centered in front of the shift rail. Then I drilled a 1/2 inch hole in the u bracket for the shaft to hold the twin sticks. The sticks were then placed on the shaft with nylon washers in between. After seeing the location I needed to heat and bend the sticks so that the ends were in line with the shifter rails. After bending them I drilled holes so that I could reuse the Dana 20 linkage pins. I then drilled matching holes in the sides of the shift rails themselves so the linkage would line up. I then measured the distance and cut and drilled the metal stock to created the correct distance for the linkage. I reused the old D20 pins and assorted washers to put it all together.
The setup works great and allows the following combinations:
Front 2 wheel high
Front 2 wheel low
Rear 2 wheel high
Rear 2 wheel low
Front/Rear 4 high
Front/Rear 4 low
It is also possible to do Rear high and Front Low and vise virsa however you will most likely explode the transfercase. ie DO NOT DO!
This setup will move the sticks over 2-3 inches towards the passenger side. I am looking for a boot to work as the old standard Dana18 boot may not work due to the lower pivot point of the levers.