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Jeep/Scout Dana 18
Jeeps had a long run using the Dana-Spicer 18 or 20 transfer case: From 1941 to 1979. These cases all had a right hand drop (front drive shaft on the right, or passenger side of the vehicle).
The Dana 18 can be identified easily, as its rear output is offset down and to the passenger side (directly behind the front output yoke). This makes this case a possible replacement for Toyota Land Cruiser cases, which have the same rear output configuration.
The front indexing hole on these cases have either a "Large Hole" (4") or a "Small Hole" (3 1/8"). The small hole was used when mated to a T84 or T90 transmission. All other Jeep cases had a large hole.
Earlier cases also used a smaller (weaker) 1-1/8" Idler shaft. Later cases used a 1-1/4" idler shaft. You should be able to measure diameter of this shaft on side of case
Use of the Dana 18 with 3.15 Gears
Must use later large hole D18. It is recommended to use a 66-79 D18 case which will require minimal grinding in order to fit the gears. It is also possible to use a D20 case w D18 guts (maintaining the offset rear output). Neither is better, just depends on what parts you have available
Idler shaft: Large hole is all 1-1/4.
Use of the Dana 18 with a Saturn Overdrive
This will allow both overdrive, plus gear splitting when using a Dana 18. Gear splitting becomes extremely advantageous when using a "Granny" Tranny, as the gears are so far apart that frequently you might wish you had a gear half way in between 2 gears. The Saturn / D18 system is especially useful for very short wheelbase vehicles such as the CJ5 and Flat fender: The overdrive mounts on the REAR of the transfer case, thus it does not use up any valuable driveline length.
Link: Full Data on Saturn OD application
Use of the Jeep Dana 18 With the Klune-V Extreme Underdrive:
These transfer cases, although used in different vehicles, all have the same bolt pattern. In terms of bolting to a Klune-V, the only way they differ is in the indexing hole diameter (see below) and the input spline count where the shaft goes into the transfer case input gear.
A Dana 18/20 mating kit PN KV100153 is required to bolt a Klune-V
Extreme Underdrive to these transfer cases. This Kit consists of a
bearing, a seal, a plate which carries the bearing and seal as well as
adapted the bolt patterns, and necessary hardware.
Indexing
The front indexing hole on these cases have either a "Large
Hole" (4") or a "Small Hole" (3 1/8"). The small
hole was used when mated to a T84 or T90 transmission. All other Jeep
cases had a large hole. The Klune-V Extreme Underdrive adapter plate used
is the same for both; a stock T90 bearing retainer is used with the small
hole while a stock T86 bearing retainer is used with the large hole case.
If you do not have this part from your current application, let us know
which you need: We can supply the Klune-V mating Kit with the correct part
included.
Mating Kit alone: PN KV100153
Mating Kit w/Small hole bearing retainer PN KV100153-90
Mating kit w/large hole bearing retainer
PN KV100153-86
Klune to Dana20 Adapter Kit Install Notes
Input Gear
These cases (with one exception) had the input gear carried directly on
the output shaft of the transmission. The case does not have an input
shaft of its own. The most common gear had an internal 6 spline where it
slides over the trans output shaft. It
was secured to the transmission shaft by a nut on a threaded
portion at the end of the shaft.
The Klune-V Extreme Underdrive main shaft used in this application is a
one piece shaft, and has the same six spline, threaded end, configuration.
Transfer Case Shifter
Use of the original shifter is usually pretty
straight forward. These cases typically came with shifters mounted to the
front of the case. While there are a number of variations, we have not
found any that will not work with the Crawler in place. Unmodified, the
shifter will exit the floorboards to the rear of where it originally came
out. Alternately, the shifter can be modified or a different shifter
installed that will have longer linkage rods and will exit at or near
the stock location.