Putting in a Dana 300

[trail rate this]

I was thinking that same thing. Just didn't think about the reamed hole.

What about turning the T-case shaft to where it has a half inch stub then drill the trans shaft, press them together, burn it in. That should be stronger.

 

[asp]

maybe, but i wanted a pin so it would be a double beveled edge filled with a ton of weld. but maybe i'll put the 2 ideas together to make it what i want.

 

[trail rate this]

want to see the shaft when done. I should have a 231 shaft tomorrow. I'm going to start playing with my idea.

 

[asp]

believe me, i want to see it too... by the way, you'll need a transmission output shaft too.

 

[trail rate this]

Yeh, I'll work on that next.

 

[asp]

keep an eye out for blown transmissions. they can be had for ~$40. i got lucky and had already rebuild an ax-15 about a month ago. i bought 2 bad transmissions and made 1 good one out of the parts...

 

[trail rate this]

Will, do. I've got a 21 spline AW4 that's good the I'm trying to sell for $50 just to get it out of my garage. I wish it was a 23 spline.

 

[asp]

haha yeah, that stinks. i started tearing into mine last night. i got it with the shifter still installed. the shift rails are frozen into the aluminum housing of the stock shifter mechanism. so i pounded the rails most of the way out with a 3lb sledge and it's soaking in PB blaster for a few days till i have time to work on it again. everything else seems to be in decent shape, but a little bit of water came out when i cracked the case open there was a ton of oil too though, so i have a feeling everything is going to be fine. didn't take any pictures because i was filthy...

 

[JeepAddict85]

haha yeah, that stinks. i started tearing into mine last night. i got it with the shifter still installed. the shift rails are frozen into the aluminum housing of the stock shifter mechanism. so i pounded the rails most of the way out with a 3lb sledge and it's soaking in PB blaster for a few days till i have time to work on it again. everything else seems to be in decent shape, but a little bit of water came out when i cracked the case open there was a ton of oil too though, so i have a feeling everything is going to be fine. didn't take any pictures because i was filthy...

those gears may be bad...you should just swap in the 4:1 kit...

 

[asp]

those gears may be bad...you should just swap in the 4:1 kit...

haha, we'll see when i open it. i highly doubt that anything is rusty, though. the whole point was to have a cheap, strong transfer case. putting $ into it would defeat my original intent of purchase.

 

[trail rate this]

a little bit of water came out when i cracked the case open there was a ton of oil too though, so i have a feeling everything is going to be fine. didn't take any pictures because i was filthy...

Mine had a lot of oil in it too. I did see some rust when pulled the input gear. Everything moves fine in it though. I put some Lucas in it, maybe that will help.

 

[trail rate this]

those gears may be bad...you should just swap in the 4:1 kit...

We can't all just drop the coin on a Klune and 32 spline outputs and a 4:1 kit.

 

[trail rate this]

Got my front driveshaft finished this morning:

Here is what I cut out:

This made sure it was straight:

Now to finish the shifter handle. This is where it is so far:

 

[trail rate this]

I drove my XJ today. I drove 60-70 miles. The D300 did well. It did start blowing oil from the vent tube. I guess I over filled it.

 

[Gravesdiggerxj]

Tried front dig yet?

 

[asp]

did you do anything about the VSS?

 

[MoparManiac]

did you do anything about the VSS?

Unless I'm thinking of something else, that's part of the transmission. A magnetic pickup I believe.

The speedometer reading comes from the t-case though.

 

[kastein]

Nope, VSS is on the t-case. OSS (output speed sensor) is on the transmission, it's a reed switch mag pickup, 1 tick per rev, on pre-98 (not a typo) and a hall/reluctance mag pickup, 4 ticks per rev, on 98+.

 

[MoparManiac]

Nope, VSS is on the t-case. OSS (output speed sensor) is on the transmission, it's a reed switch mag pickup, 1 tick per rev, on pre-98 (not a typo) and a hall/reluctance mag pickup, 4 ticks per rev, on 98+.

That makes sense. Does the VSS play more of a role on OBD-II rigs than OBD-I (or 98+ like you mentioned)?

I know that if I don't have a working speedo on mine it's not a problem.

 

[asp]

i know vetteboy had issues with his when his VSS wasn't working. there are 32 spline output kits to solve that problem, but then what the heck is the point of doing this on a budget?

i know the stock D300 VSS is similar in principle to the np231 and stock xj setup. i can't remember how many ticks per rev the D300 is though.