Twin stick Dana 20 J shift - cutting

[GloNDark2]

I am finally getting around to installing my Toms Bronco parts twin stick. Got my old j-shift out, removed the front drive shaft to get easier access at cutting the shift rails. Went to town with a sawzall and a good metal blade and promptly went right thru the blade without making a dent in the shift rail. Got another blade and went much MUCH slower this time. Was able to get about 1/4” before the blade was toast again.

Anyone have any other ideas on how to cut the rails? Or should I just man up and take the t-case out to get it done?

[904Bronco]

Re: Twin stick Dana 20 J shift - cutting

Well mine was out when I did it on my 77...

[Action]

Re: Twin stick Dana 20 J shift - cutting

I used a 4 1/2" grinder with a cut off wheel while in my Bronco........

[GloNDark2]

Re: Twin stick Dana 20 J shift - cutting

I used a 4 1/2" grinder with a cut off wheel while in my Bronco........

I tried getting my grinder up there. I might have to take another look at it.

[71BRONCO71]

Re: Twin stick Dana 20 J shift - cutting

Sounds like its time to make a bigger hole in the tranny hump

[GloNDark2]

Re: Twin stick Dana 20 J shift - cutting

Not on this Bronco. I'd pull the t-case out before I did that. I have a column shift auto and and the floors are in great shape. No sense in cutting it up if I can avoid it.

I grabbed some 4" cut off wheels for my old makita 4" grinder and some cut off wheels for my dremel at Lowes today going to try that and see if I can get it done. If that doesn't work, i'm going to put the floor jack under the t-case and pull the crossmember. I should have all the room I need if I pull the cross member out.

[Action]

Re: Twin stick Dana 20 J shift - cutting

Well you know how memory's are......I know I used a cut off wheel......Im sure I did it from the bottom but could be wrong.....You almost need a hole like ryans to install the twin sticks.......
Good luck

[GloNDark2]

Re: Twin stick Dana 20 J shift - cutting

I was able to get it from the bottom with a 4.5” cut off wheel (and the guard off the grinder hahaha). Cut thru it like butter. It would have been way easier to cut the floor but since I still have carpet and the floors are on good shape I didn’t want to mess with it.

Now I have to find a good twin stick boot and finish it up. Thanks everyone!