Transform your off-road experience with a Dana 20 twin stick conversion that delivers independent front and rear axle control. This comprehensive modification replaces the restrictive factory single shifter with dual independent controls, unlocking advanced driving modes previously impossible with the original Dana 20 transfer case configuration.
The Dana 20 transfer case, found in classic Jeeps, Broncos, and other vintage 4WD vehicles, becomes significantly more versatile when equipped with aftermarket twin stick shifters. The Dana 20 is a very good recipient for a twin-stick conversion, making it an ideal candidate for this popular modification among serious off-road enthusiasts.
Understanding Dana 20 Twin Stick Technology
What Makes Twin Stick Different
The fundamental advantage of twin-stick conversion lies in independent axle control. The twin sticks allow for shifting one rail at a time (front or rear), whereas the original shifters have both rails connected together, making it harder to shift. This separation provides unprecedented control over your vehicle’s traction distribution.
Traditional Dana 20 transfer cases utilize a single shifter mechanism that controls both front and rear outputs simultaneously. The twin-stick conversion removes this limitation by providing separate controls for each output, enabling advanced techniques like front-only or rear-only low-range operation.
Enhanced Driving Modes Available
With a proper twin-stick installation, operators gain access to several additional transfer case modes. An aftermarket twin-stick shifter conversion can simplify shifting and offer transfer case modes not available with the original single-shifter mechanism, such as two-wheel-drive rear low range and front-only. These modes include front-wheel drive (high or low), rear-wheel drive low range, and independent selection of high or low range for either axle.
Installation Process and Key Components
Essential Hardware Requirements
Modern Dana 20 twin-stick kits include comprehensive hardware packages designed for straightforward installation. These kits come with the hardware and instructions required to create a clean and highly functional shifter upgrade. Quality manufacturers like Novak Adapt provide complete conversion packages with precision-machined components.
The conversion typically requires removing the factory interlock mechanism that prevents independent front and rear operation. Removal of this interlock allows for the added function of 2WD/Low and front-wheel-drive high or low to the 20—if you have the “twin-stick” version. This modification fundamentally changes how the transfer case operates, providing the flexibility that makes twin-stick conversions so desirable.
Professional Installation Considerations
While mechanically inclined enthusiasts can tackle this conversion, proper execution requires attention to detail and understanding of transfer case internals. The modification involves accessing internal shifter rails and removing factory interlocks, necessitating partial disassembly of the transfer case housing.
Quality aftermarket suppliers provide detailed installation instructions, but having transfer case experience significantly improves success rates. Consider professional installation if you lack experience with internal transfer case modifications or lack proper tools for the job.
Performance Benefits and Off-Road Applications
Advanced Traction Management
The primary benefit of the Dana 20 twin stick conversion centers on enhanced traction control capabilities. This kit allows you to separate your forward gears from the rear gears, allowing you to do a front-only dig or a rear-only dig, or both together. This functionality proves invaluable in challenging terrain where traditional 4WD systems fall short.
Rock crawling enthusiasts particularly benefit from independent axle control, allowing precise wheel placement and traction management on technical obstacles. The ability to engage only the front or rear low range provides options for navigating challenging terrain that would be impossible with conventional transfer case operation.
Improved Shifting Performance
Many Dana 20 owners experience shifting difficulties with factory configurations. My existing transfer case is fine, but the shifter rattles enough to make me crazy, reports one enthusiast who opted for a twin-stick conversion to address shifting issues. The aftermarket twin-stick systems often provide smoother, more positive engagement compared to worn factory mechanisms.
Choosing Quality Twin Stick Components
Manufacturer Selection Criteria
When selecting a Dana 20 twin stick conversion kit, component quality and manufacturer reputation matter significantly. Quality is a priority here when choosing conversion components, as inferior kits can lead to premature failure and poor performance.
Reputable manufacturers like JB Custom Fabrication and established transfer case specialists provide proven conversion kits with quality materials and comprehensive installation support. This kit is made in the USA and includes necessary hardware, boots, and knobs for complete installation.
Material and Construction Quality
Premium twin-stick kits feature stainless steel construction and precision machining for durability and performance. Stainless twin stick T-shifter options provide corrosion resistance and long-term reliability in harsh off-road environments. Quality kits also include properly designed boots and hardware for weather protection and professional appearance.
Maintenance and Long-Term Performance
Ongoing Care Requirements
Dana 20 twin-stick conversions require minimal additional maintenance beyond standard transfer case service. However, the removal of factory interlocks and modification of internal components necessitates attention to proper lubrication and seal integrity. Regular inspection of shifter boots and linkages ensures continued performance and prevents contamination.
The conversion does alter internal stress patterns within the transfer case, making quality installation and proper setup crucial for longevity. Following the manufacturer’s torque specifications and using recommended lubricants helps ensure reliable, long-term operation.
Troubleshooting Common Issues
Most twin-stick conversion problems stem from improper installation or inferior components. Binding shifters, incomplete engagement, or difficulty finding gears typically indicate adjustment issues or component interference. Quality kits include comprehensive troubleshooting guides and technical support for addressing installation challenges.
The Dana 20 twin-stick conversion represents one of the most effective modifications for serious off-road enthusiasts seeking enhanced control and capability. The conversion unlocks advanced driving modes impossible with factory configurations while often improving shifting performance and reliability. When combined with quality components and proper installation, twin-stick conversion transforms the Dana 20 from a basic transfer case into a sophisticated traction management system capable of handling the most challenging terrain.
Investment in quality conversion components and professional installation pays dividends in performance, reliability, and long-term satisfaction. For Dana 20 owners serious about off-road capability, twin-stick conversion offers unmatched control and versatility that elevates the entire driving experience.