Improving the Dana 300

[HillBillE]

I usd the write ups from 4x4wire, to do a couple mods on my T-case.
Very well written, and easy to follow. http://www.4x4wire.com/tech/dana300/

Things to do when............
..........................it's below zero for 2 weeks.

Improving the T-case:

In addition to new roller bearings, shift fork pads and seals, I ground the rear shift rail detent a bit more, allowing me to have front axle hi range (rear in nuetral) The way it's done, I can't put the rear axle in low and front axle in hi, binding the case up.
With just the twinsticks, I could only have front axle only low, now I can have front axle only high. Not sure what I'll use it for, but it looked like a cool mod to do!

I also drilled and tapped the case, to install a sight tube. Since I'm clocking my T-case, the fill hole will be 2-3'' higher than normal, so I can't use that to check fill level anymore.
The red arrows are where I drilled and tapped (1/8th'' NPT) And the dotted yellow lie is where the clear sight tube will run.

Close up of new tapping:

[HillBillE]

Finally got the peices for the site tube. 1/8th'' male pipe x 1/4'' tubing.

Afterwards I did find some 1/8th pipe to 3/8th'' tubing adapters, I may go with that, as it's easier to see. Here is the finished T-case with the 1/4' site tube attatched:



As this is how the case will lay when clocked, using the fill hole to check the level wouldn't work very well.

[miljeep]

looks nice. Maybe some day I will get off my butt and post something cool like this.

[02tj]

nice, any shots of it in the jeep?

[HillBillE]

nice, any shots of it in the jeep?

Not yet, I should have the motor bck from being rebuilt this Thursday (1 Feb 08), then everything's going back in. I'll have some shots of it in, and what had to be done for the clocking and crossmember, along with the skidplate(s). HB

[BESRK]

Are you gonna twin stick it? I just ordered the stainless twin stick setup off eBay for my 300. I got a Teralow 4 to 1 kit in trade and picked up a clocking ring too. Plan is to flat mount it as much as possible and build a nice belly skid for it.. maybe skin it with 3/16" or 1/4".

I like that color blue..

[HillBillE]

Yes, I had already twinsticked it, while it was apart, I also ground the shift rail, to allow Front axle HI (rear axle in N). That mod is also in the 4x4wire link in my first post. Very easy to do while the case is apart.

[korisu56]

What are the prereq's for a belly up? What do you have to adjust? If I could just take 1/4" steel and cut and drill holes, I would, but I have no idea how to compensate the driveline angles....

[HMRRSQ]

I remember thoses days of having a T-case apart on the bench.

[HillBillE]

What are the prereq's for a belly up? What do you have to adjust? If I could just take 1/4" steel and cut and drill holes, I would, but I have no idea how to compensate the driveline angles....

Not sure on the CJ. I have a 1'' body lift, which will help, but I may have to do some body clearancing on the floor board for the T-case. The lowest part hanging down will be the tranny mount, about 2'' lower than the clocked T-case. The front drive shaft will need to be lengthened, but from my research/questions I've asked, it won't hit the starter on the 258.

I hope to have my motor back tomorrow,so I can start fitting things up. Problem is, it's -20 below with windchills of -40 to -60 right now!! Been home with the kids (school cancelled) for 2 days now, instead of at the shop getting ready!!

Once I get there, I'll keep posting pics of the progress, crossmember, skid paltes and clearance issues.

I'd like to put a large skid plate, seperate from the crossmember. I may end up with 2, one in front one behind the crossmember.