Dana 20 speedo removal

I bought a new speedometer cable and it won't seem to go into the dana 20 transfer case. Looks like I can only get maybe a 1/4 inch of the cable into the hole. Can I trim the cable to make it fit or will it mess up the square? I've looked into the hole and it looks like there may be something in the hole but it's hard to tell. How much of the speedo cable end will go into the hole? Also, what size socket will unscrew it? I'm thinking I need to take it out and clean it..............I've tried every socket I have but nothing will fit.....

 

7/8" socket for the adapter. I had to grind down the outside of one to fit some of them.

IIRC about 1/4"-1/2" of the cable goes down into the driven gear shaft.

 

1/4" is all that goes in now, I think 1/2" would prolly fit but doubt it. I sure would hate to grind a socket but I guess whateer it takes.......

 

It may have a piece of broken speedo cable already down in the hole from an earlier speedo cable that broke off in it. Could be the reason the new one will not go far enough in.

 

You may not have to. Some housings have the clearance and some don't. Buy a cheap socket and grind that instead of a good one. I bought a cheap thin walled Performance Tool 6 point 7/8" socket and ground the outside to fit between the casting of the output housing and the hex on the adapter. Has worked fine for 2 or 3 years now and I use it almost weekly.

 

You might also try giving the output shaft a spin while pushing down, but not too hard, on the cable.

 

Thanks for all the inputs. I'll get a used socket and grind it. Using a mirror it looks like it may have some of the old cable still in it. We'll see. Thanks for the inputs and I'll update when its fixed. Learning new things everyday!!!!! I guess this is what jeep owners look forward to huh?!?!?!

 

Try shooting some compressed air in the hole.
It may pop that stuff out.
Also you may need to corkscrew something into it to pull it free. Like a drywall screw ground thin enough.