dana 24 rebuild info

[jd72hiboy]

My dana 24 transfercase in my 72' f-250 plow truck has developed quite a bit of play on the front and read driveline output shafts I need to rebuild it this summer. I found a rebuild kit and poly mount kit from jeffs bronco graveyard, does any one have a PDF of the rebuild procedure?

[Redcap]

You would be better off finding a NP205.

[averagef250]

Second NP205 vote.

The D24's just don't live under heavy use. There are no PDF's. D24's were antiques when they were still being used by Ford.

[eggman918]

They are very simple,I think that info on a dana 18 will help if you can find it a 24 is a larger scale 18.
the only trick i can think of is there are a set of lose roller bearings that are hard to get to stay together.
I froze the shafts and held rollers in place with assy.lube, that kept them together long enough to assemble.
there are no more surprises i can recall, It is a doable project
the are dinosaurs and if I had not just rebuilt my 24 I would be looking for a 205 also,I guess in another 20 years I will be trying to find a 205 which will THEN be a dinosaur too

[jd72hiboy]

Thanks so much for the info, I'll try to find info on the dana 18. The 24 seem to be pretty strong (it lasted 38 years, mostly plowing) so im sure it will last the rest of the trucks life.

[eggman918]

One thing I forgot the lip seals for the yoke's that come in the kits fit but are not the right applacition.
you need to use two in each housing back to back one sealing in oil the other sealing crap out.
I used the seal that was the thinnest so that I could stack 2 in the bore ,I think they were .312"or.375"thick I cant recall

[averagef250]

Thanks so much for the info, I'll try to find info on the dana 18. The 24 seem to be pretty strong (it lasted 38 years, mostly plowing) so im sure it will last the rest of the trucks life.

How many miles were actually put on the truck? I get 20K miles from a 24 before the input bearings get sloppy. I've gone through a good lot of 23 and 24 dana cases, worked them hard in my own trucks and found that they are tough, they don't break, they shift poorly and the upper bearings, specifically the input bearings fail far sooner than they should.

If I were rebuilding one today I would order all my bearings individually getting sealed -not open or shielded- bearings for all the upper bearings and just buy a gasket and seal kit from a parts supplier. The sealed ball bearings should last longer.

[jd72hiboy]

Thats great advice, Im guessing about 80K on the truck total. I havent located a junk yard np205 that I can afford. The problem Ive found is getting parts for this t-case. I found the poly mount kit and the bearing and seal kit from jeffsbroncograveyard. Would be nice if i could find bearing dimensions for the upper bearings, Ive got Mesa bearing in Grand Junction CO and they usually have anything I need. Gaskets may be another story. Has any one fabriacated a brace for the 24 like some of the 205's have? I assume mounting slop is a major contributor to the bearing and u-joint issues.

[eggman918]

Average F-250 has sound advice all the bearings are standard,if you can disassemble first then order bearings it will cost you less and you can get sealed ones.
The seals are standard also,the roller bearings are the only thing that might be hard to find,but they only wear when in low range so they may be OK
If I can be of any help please let me know.If you can't find a pdf don't worry they dont have any nasty surprises inside,If you dont get a kit let me know and I will pull off one housing and measure gasket thickness so you can order the right thickness

[eggman918]

Now that the filthy beast is down for maintenance I am going to "fix" that top end oiling problem.....that and the 4BT swap will keep the beast going longer than I will

[william_aske]

Guys - I just rebuilt the Dana 24 I've got in my Tahoe over Christmas. I've looked for the last few years for info on this case without any luck. Hopefully some of the pics should help: http://s688.photobucket.com/albums/vv24 ... 20REBUILD/

Let me know if you have any questions.

[jd72hiboy]

right on, Ill check it out

[davesoehren]

im about to rebuild my 24 for the first time in it's life...it's now at 155K and still going but it's getting sloppy it's in a 70 and it's 42 years old.... found some info on it...
http://www.fordification.com/tech/image ... 72F250.jpg
http://www.fordification.com/tech/schematics_g.htm

[sopikp1]

Wouldn't trade my rebuilt 24 for anything! Just picked this up today. Good luck!