dana 300 swap

[preacherman]

I have a 91 GW with a 727 and a np229. I am pretty sure (I still have to confirm) that the VC is shot in my case. I am building this rig for expedition wheeling and would like a better transfer case for moderate wheeling. I am looking at a d300. My understanding is that it will bolt right up but will have to be clocked upside down. My questions are:

Will I need a clocking ring?
I have heard the front driveshaft might not clear the tranny???
Will I have to change the rear driveshaft?
How will I have to change or modify my transfer case crossmember?
What else am I missing?

Thanks!

[wickedwagon767]

I have a 91 GW with a 727 and a np229. I am pretty sure (I still have to confirm) that the VC is shot in my case. I am building this rig for expedition wheeling and would like a better transfer case for moderate wheeling. I am looking at a d300. My understanding is that it will bolt right up but will have to be clocked upside down. My questions are:

Will I need a clocking ring?
I have heard the front driveshaft might not clear the tranny???
Will I have to change the rear driveshaft?
How will I have to change or modify my transfer case crossmember?
What else am I missing?

Thanks!

First off, an NP208 part-time, lever-shifted transter case found in 1980-87 Fullsize Cherokees and J10/20 pickups with the "command-trac" 4wd option is a very simple swap for your application. They are fairly durable and reliable for most mild-to-moderate wheeling condtions.

If you are set on a Dana300, you will need MUCH more than a clocking ring. You will need a complete "flip kit" that a handful of companies make. The shifter linkage will not work upside down, so cable shifters are utilized. Yes, the driveshaft will interfere with the tranny pan if you don't install a lift on the vehicle. Either you will need to install a lift for bigger tires (which I assume you probably want to do anyway) or you will probably have to have a driveshaft built with a VERY thin tube that won't be very durable. As for the driveshaft, your tape-measure will let you know when you're done,but the length shouldn't be an issue.

Not sure on your crossmember, I'll leave that to someone else:thumbsup:

[jeeping1974]

I too would go with an NP208 t-case for your vehicle. You have a driver's side drop front axle and the dana 300 t-case is passenger side drop. There are a number of companies that make flip kits and shifters to make a dana 300 a driver's side drop like wicked said.

Your cross member may need to be modified as well so that teh dana 300 t-case can be clocked down far enough to clear the tranny pan or you can look into having a driveshaft built with a pillow block that is mounted to the frame then angles down to the front axle. You would not have to do this with an NP208.

[preacherman]

Thanks for the reply a few more questions.

Does the NP2o8 use vacuum like the np229? I hate the vacuum actuator.

My understanding is the 208 will require a new front drive shaft?? Is that correct?

Several companies now offer cable shifters for the dana 300 so the plan is if I get the 300 to put on dual cable shifters.

[jeeping1974]

The 208 is lever action (95% sure). I think that you can reuse your driveshaft. If the yoke is different, a driveshaft shop can swap the yoke to the proper size for you.

You'll need a new front and rear driveshafts if you go with a dana 300.

[billyrb]

208 is non-vacuum. You will reuse your front shaft, but the rear will need to be lengthened by a few inches (most local dshaft shops will do this and include balancing & new joints for around $125-150.

[Long&Low]

You CAN make a home made D300 flip kit. I made one that went into a YJ I had. Do a search on Pirate for it, lots of good info. If you flip it then go with cable shifters. I ended up using International Harvest Throttle control levers to shift the axles, one for each output. It worked, but I never really got my flipped D300 to not leak gear lube.

[Sambo]

http://www.pirate4x4.com/forum/showthread.php?t=785197

[Chevelleguy]

If the viscous coupling case is not cracked, you can pin it and continue to use it for $10. I did mine in '03 and it is still going strong but is now a part time case only. One of the guys on the forum from Alaska modified a Dana 20 twin stick kit to fit his 229, now he no longer has to deal with the vacuum system. It turned out real slick.

[preacherman]

If the viscous coupling case is not cracked, you can pin it and continue to use it for $10. I did mine in '03 and it is still going strong but is now a part time case only. One of the guys on the forum from Alaska modified a Dana 20 twin stick kit to fit his 229, now he no longer has to deal with the vacuum system. It turned out real slick.

That's a good idea. Do you know his screen name so I can do a search?

[malodin]

or if you are going for a lift in the future, slap in a chevy passenger side drop d44 that gives you a spring over setup in the front and do a tts flip kit in the rear netting you 5-7" of lift and the d300 goes right on in normal configuration (granted you will then need steering work, and driveshaft work)

[jeepdreamer]

Ok,
I LOVE the dana 300! I believe its one of Jeeps crowning moments. That being said, decide what your goals are and research it to death. Your 229 is, IMHO, a turd. Others will strongly disagree, thats fine. If you goal is dependability and least expensive... I'd also swap in an NP208. Go through it first and reseal everything, then run it as is. I've been plesantly surprised with the one in my DD. Other than constantly leaking, no issues.
If your building something more robust then the easiest way would be bolt on the 300 and swap the front axle to a pass. side drop. I believe it would be cheaper and less leak prone than the "flipped" 300. The 300 is plenty strong for fairly stout setup. Ive run em behind v8s and 38" tires. The twin stick option is nice too.
Good luck

[Chevelleguy]

That's a good idea. Do you know his screen name so I can do a search?
AKAMC. I found the post and the one he had up on his AMC Eagle forum but all the pics have been deleted.

[preacherman]

Ok,
I LOVE the dana 300! I believe its one of Jeeps crowning moments. That being said, decide what your goals are and research it to death. Your 229 is, IMHO, a turd. Others will strongly disagree, thats fine. If you goal is dependability and least expensive... I'd also swap in an NP208. Go through it first and reseal everything, then run it as is. I've been plesantly surprised with the one in my DD. Other than constantly leaking, no issues.
If your building something more robust then the easiest way would be bolt on the 300 and swap the front axle to a pass. side drop. I believe it would be cheaper and less leak prone than the "flipped" 300. The 300 is plenty strong for fairly stout setup. Ive run em behind v8s and 38" tires. The twin stick option is nice too.
Good luck
This rig will be a "back country" rig with most of my exploits being long trips to remote places with my family. I will be running a 4 inch lift with 31's and will be using the rig to explore the southwest. The terrain will be moderate to mild desert travel with a few mountian trails thrown in for good measure. I have a lifted TJ if I want to go crawling so this will not be a hard core trail rig. Think: Something I can drive to Ouray with the family, wheel and camp in all week and drive back to Texas with few issues (at least few transfer case issues). This will also be my daily driver. The more I reasearch it the more I like the 208. I am NOT IMPRESSED AT ALL with the 229! From previous experiance I have a hard time telling it is even working. I want something reliable that will work when I shift it into 4wd and will not leave me stuck on some sand hole in Mexico.

The reason I like the 300 is beceause I had on in a CJ and loved it. It was everything a transfer case was susposed to be. It had gears, a real lever moounted on the floor and never gave me 1 problem.

[Chevelleguy]

Sounds like the 208 all you need.

[jaber]

Not to high jack, but I have a divorced 300 in the Willys I got. Can I just remove the input yoke and housing and mount it to a 727?

[fullsizejohn]

208 will serve you well !
x2:D

[rockjeep44]

Go with the 208. I beat on mine like it owed me money. Bang for the buck you can't beat it.

[jeepdreamer]

Sounds like the 208 is dead on the money for ya. I dont know where in west texas you are but im stationed in El Paso. If youd like to come see mine in person? The 208 even has a lil tiny bit better low range than the 300! I would find one (not impossible), go through it completly, and run it. Maybe a good skid plate to protect it from the oops's. Thats the only fault is the "fragile" aluminum (or magnisium?) case vs the 300 cast iron one.

[rockjeep44]

Not a problem if mounted well

[jeepdreamer]

Hey Jaber... Can you send me a pict or two of your divorced dana 300?? I've wondered if they ever made one but nobody could confirm it for me! Thanks!

And i just meant that a skid plate goes a long way to insure no damage to the t-case. and the iron 300 would survive an accidental hit better.

[jaber]

It's not at my house, but am going over to it today. I also want to get better pics to make sure I am right in my ID of it. I'll post them today, hopefully...

[jeepdreamer]

Ok,
I've just never heard, let alone seen, a divorced dana 300. Doesnt mean they dont exist... Jeep does funny things sometime. I would be willing to bet that its a dana 20 though..? If it was a 300... How cool would it be to mount it behind one of the old "Brownie" Over/Under drives!?!?:D

[jaber]

Well, I guess I am still learning. The more I look at this, I am wrong. I now believe its a divorced D-18. Heres the pics so you guys can set me straight...

http://i252.photobucket.com/albums/hh14/jeffaber/Parts/Willys008.jpg

http://i252.photobucket.com/albums/hh14/jeffaber/Parts/Willystcase001.jpg

http://i252.photobucket.com/albums/hh14/jeffaber/Parts/Willystcase002.jpg

http://i252.photobucket.com/albums/hh14/jeffaber/Parts/Willystcase003.jpg

http://i252.photobucket.com/albums/hh14/jeffaber/Parts/Willystcase004.jpg

[COLOFIREMAN]

Well, I guess I am still learning. The more I look at this, I am wrong. I now believe its a divorced D-18. Heres the pics so you guys can set me straight...

Yep, it a Dana 18. Both front and rear coming off of the same shaft. IIRC only imports had the same type T/C. Cool though I've never seen one up close, and with all the "Jeep Blood" coating it......;) :D


From the look of the cab cutting that truck didn't come with it, was it a 2WD???

[jaber]

Yep, it a Dana 18. Both front and rear coming off of the same shaft. IIRC only imports had the same type T/C. Cool though I've never seen one up close, and with all the "Jeep Blood" coating it......;) :D


From the look of the cab cutting that truck didn't come with it, was it a 2WD???

It does not appear to have been a 2x. Someone stuffed a Ford "Y" block V-8 and 4 speed truck trans into it. It has this t-case and the rear d-shaft is only about 24" long. It has the twin sticks "extended" from the case about middle of the bed to the firewall. Real goofy set up. It is in my '51 Willys P/U.