I've only done it with a dana 300, but a dana 20 should be about the same. To get the interlock out you
need to pretty much disassemble the whole case. You need to remove both shift rails from the shifter
housing (the piece that contains the front output shaft's front bearing race). Each shift rail has detents
and a ball with a spring, to hold it in the proper position for high, neutral, and low - rotate the shift rail to
get the ball out of the groove, then you can pull it out. There are two plugs about 1/4" in diameter on the
side of the shifter housing that you need to remove (it's nearly impossible to remove them without
destroying them - I think I got some replacements from Outback Parts) to get the interlock plugs out. It's
a good idea to shim the springs while you're at it, to help keep the shifters from popping out of gear.
After saying all that, I'd recommend that you see if it will shift into rear-wheel-drive low range before you
disassemble - you may not need to remove the interlock at all. You'll need to disconnect the
shifter linkage, and operate the shift rails manually. If you find that you don't need to remove
the interlock, then you'll need to fabricate a twin-stick setup (I modified a Currie twin-stick
conversion that's made for jeeps - it didn't require any welding/grinding of the shift rails, but
you need to bend or cut/weld the shift levers). I went ahead and removed the interlock
on mine because I already had the transfer case disassembled for a rebuild and for installation of
a Tera gearset.
>Also how do I gst the low range gear out?
Which gear do you mean?
Later,
Curt
