| The first step is to
acquire the full set of gears from the Dana 18 transfer case. This must be
the series with the 29 tooth top gear and 1 1/4" idler
shaft. Then dismantle the Model 20 transfer case and replace all the gears with
the Model 18 gears. The low range gear in the lower end doesn't clear the case so it is necessary to grind the inside of the case for clearance.
You will find you are one gear short in the top assembly. The correct one
is not available new. The gear needed is the top gear from the Bronco
Model 20 transfer case. It is the top sliding low range spur gear. It has
33 teeth and 15 spline with the Dana number 18-8-58.The low range gear in
the top end also doesn't clear the case so it is necessary to grind the
inside of the case for clearance.
The end result will be a 2.46 to 1 ratio instead of the stock 2.03 to 1
ratio.
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