These instructions are for the adapter kit :
| KV200003-KIT |
1. Press the 6307 bearing into the aluminum adapter. Lock it in place with the snap ring supplied in the kit. Press the main shaft into the bearing, with the 6 spline part sticking out the end where you put the bearing. Install 6 2” studs into the Klune side of the adapter. Thread them through so they are flush with the back, but not protruding. You can use locktite on these if desired.
2. Remove the stock adapter from the Bronco Dana 20. There are 13 loose roller bearings inside: If you prop the Dana 20 on a bench so the input gear is facing up, vertically, when you pull the adapter away, The input gear will come away with the stock adapter and those 13 rollers will still be laying in the pocket in the out put shaft. You will need these rollers, and of course you will NOT wanting any floating around in the Tcase. You will need to remove the input gear and snap ring from the stock adapter spud shaft: You will need these parts
3. Put the input gear and snap ring onto the adapter shaft the same way they came off the Bronco adapter (The dog-clutch engagement teeth go toward the Bronco Dana 20)
4. Prop the Dana 20 on a bench so the input gear is facing up, vertically. Use some axle or tranny set up grease: Arrange the 13 roller bearings into the pocket in the Dana 20 output shaft. The grease will help keep them in place while you are loading them. Once all 13 are in there, they fit precisely.
5. Lower the adapter assembly (as assembled in (1) above) into the Klune. You will need to use silicon RTV sealant to seal up this connection. Secure the adapter to the Dana 20 with 6 socket head cap screws.
6. Put the foot mount and the .080 shim spacer over the studs on the adapter housing. Make sure you have the foot mount rotated how you will want it in your final install (see clocking instructions in KV install manual). The “Foot” portion of the mount faces toward the Klune. You might test assemble this onto the Klune and put the whole assembly in place in the vehicle to verify clocking.
7. Once you have the clocking figured out, you will need to use silicon RTV sealant between the adapter, foot mount, shim and the Klune. The adapter is then secured to the Klune using a flat washer, a lock washer and a nut on each of the studs.
I think that should cover it, with details of the shifter and other items covered in the Klune Install Manual. If you need to refer to this and do not have it, it can be found in the Klune-V section of the website www.high-impact.net