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View Full Version : Dana 300 in a WJ? Possible?



ron4x4
11-17-2008, 03:55 PM
Hi Guys,
I'm Mulling over the Idea of putting a flipped Dana 300 in my 2001 Grand and I have a few questions.
First I guess, is this a viable swap? I like the Idea of the gears instead of a chain. There also seems to be more gear options available.
What input shaft would I use?
Is one Flip Kit better than another?
Have any of you done this swap and what do you think?

Thanks,

Ron

nierace
11-17-2008, 04:13 PM
Do you have I6 or V8? If you have the I6 you can definitely get a input or possibly use your existing one to swap it in(Don't know if it will I don't think it will but don't know too much about the D300). You're going to do some funky stuff with the linkage but definately do-able.

If you have the V8 you may have trouble finding the input but advanced adapters and jbconversions would be your best bets.

ron4x4
11-17-2008, 05:55 PM
Do you have I6 or V8? If you have the I6 you can definitely get a input or possibly use your existing one to swap it in(Don't know if it will I don't think it will but don't know too much about the D300). You're going to do some funky stuff with the linkage but definately do-able.

If you have the V8 you may have trouble finding the input but advanced adapters and jbconversions would be your best bets.

Thanks for the reply, I do have a 4.7, I am not too worried about linkage, I am fairly sue I can make it work with some creative thinking. I don't know if the there is an input shaft for the D300 that will fit, to the 545RFE, Guess it is time to call. Anyone else have any thoughts?

ron4x4
11-17-2008, 06:05 PM
Okay I just got off the phone with Advanced adapters, He said and I Quote "Your tail shaft from the 545RFE is 23 spline and the 6 bolt housing will bolt to the Dana300 6 bolt housing with a flip kit with NO issues." "The only thing to work out is the Linkage". My response was "Really?" Yes was the answer, Now What do you guys think?

Thanks

AgitatedPancake
11-18-2008, 01:07 AM
I think that's very interesting, I've heard about that case so I'll have to actually check it out now =D

ATL ZJ
11-18-2008, 01:23 AM
Anything is possible. 300s are good cases. They tend to have case failures under extreme use and esp. when paired with a doubler, but for your application it should be a big strength upgrade. You could benefit from doing a lot more research- not necessarily GC related, but about the 300 in general. There are more benefits than you listed. one is twin-stick ability.

You can always make cable shifters using parts from your local hardware store or McMaster-Carr. Or buy one of the shifter kits available such as this one: http://jbfab.net/Merchant2/merchant.mv?Screen=CTGY&Store_Code=JCFCS&Category_Code=Shifters

I use their shifter kit on my 205 but they have d300 shifters too. I really like mine and the price is cheap for the quality you get.

ATL ZJ
11-18-2008, 01:25 AM
Please note that any advice I have given may lead you to cut holes in your floor, disconnect vehicle information center 4wd lights, and cause you to spiral down a pathway of reckless abandon in pursuit of enjoying your jeep to the fullest.

nierace
11-18-2008, 06:32 AM
See if you can find out how long the amount of exposed input shaft is. On the V8 WJ its like ~3" (2.50" exposed) vs. the I6's ~3/4"(.840" exposed)

That'd make that alot more tempting of a option if its plug and play :O

nierace
11-18-2008, 06:43 AM
I looked around briefly, I think AA is incorrect in this case, even though its the same 6 bolt pattern and 23 spline the amount of exposed input shaft doesn't match (So your transmission output seal will leak and you'll only have contact on the tip of the shaft). The Dana 300's appear to come with the standard 2 options of .840"exposed (For I6 with auto) or 1.55" exposed (For I6 with manual).

Its 5:45 so maybe I missed something.

ron4x4
11-18-2008, 11:30 AM
I looked around briefly, I think AA is incorrect in this case, even though its the same 6 bolt pattern and 23 spline the amount of exposed input shaft doesn't match (So your transmission output seal will leak and you'll only have contact on the tip of the shaft). The Dana 300's appear to come with the standard 2 options of .840"exposed (For I6 with auto) or 1.55" exposed (For I6 with manual).

Its 5:45 so maybe I missed something.

If I remember right the end of my of the shaft poking thru the adapter is 1 13/16" I'll have to double check it obviously, Before I buy one.
I have my eyes on a dana 60 at the moment, so I may have to squeeze in a new case and flip a D300 if it will be strong enough! It Might just be the way to go.
The Idea will be D60 Front with Corp14 rear and a strong enough case to not let me down.

Thanks for the Reply's

nierace
11-18-2008, 11:32 AM
Theres no F'n way that its a plug and play operation.

Heres a pic of a D300:
http://www.pirate4x4.com/productreviews/scrambler/Part2Pic3instaled.JPG

Heres a pic of a 242HD for V8:

http://i86.photobucket.com/albums/k120/nierace/Transfer%20Case/DSC00630.jpg

Big difference in exposed length of the input. However if you can move your input over that'd be awesome.

ron4x4
11-18-2008, 11:36 AM
Dang, Nierace! Nice going, I'd have to agree there is no way that is plug and play. Big difference! I wonder then if there is a replacement input shaft for the D300 _ I love researching this type of crap! T
Thanks

ron4x4
11-18-2008, 11:44 AM
Maybey this is what I would need!

http://www.jbconversions.com/pages/products/dana300/inputgears.html

nierace
11-18-2008, 12:00 PM
Yeah that's what I wanted for a 241OR but they told me they don't make one for the WJ.

You might want to check the price also, the one from NOVAK for the Dana 300 is $550 I shit you not :O

ron4x4
11-18-2008, 12:19 PM
Yeah that's what I wanted for a 241OR but they told me they don't make one for the WJ.

You might want to check the price also, the one from NOVAK for the Dana 300 is $550 I shit you not :O

Holy Crap that is 200 more than the freaking case! The more I look at options for this case the more expensive it gets.

maybe I'll just stick with the HD231 option from JB Con.

ATL ZJ
11-18-2008, 01:26 PM
Holy Crap that is 200 more than the freaking case! The more I look at options for this case the more expensive it gets.

maybe I'll just stick with the HD231 option from JB Con.


Who is ripping you off $350 for a dana 300? They go for 150 here and on pirate. 231s suck, make the leap to a gear driven case.

nierace
11-18-2008, 01:47 PM
Yeah I didn't go to a 231 cus I decided I'd rather save my $ for a atlas or stak for when the time comes.

ron4x4
11-18-2008, 02:10 PM
Who is ripping you off $350 for a dana 300? They go for 150 here and on pirate. 231s suck, make the leap to a gear driven case.

Few places on Craigslist--- I'll look on Pirate,

ron4x4
11-18-2008, 05:16 PM
looking at this pict it looks like it would work it looks longer than the other pict of the 300
http://pirate4x4.com/forum/attachment.php?attachmentid=402013&stc=1&d=1226432083

nierace
11-18-2008, 05:41 PM
I'd bet ya that's setup for the 1.55" (for manual trannys) and the other I posted is the .84" (for auto trannys).

That might not even be the input that came with it, you can see he has the spacer block that comes with the flip kit installed so he may have swapped in a different input too :P

speedmontzj
11-18-2008, 05:47 PM
the output on my trans on my zj bottomed out in the input of the 300 before the case would butt up against the trans. other than that it was bolt in, kinda.:D

speedmontzj
11-18-2008, 05:48 PM
I'd bet ya that's setup for the 1.55" (for manual trannys) and the other I posted is the .84" (for auto trannys).

That might not even be the input that came with it, you can see he has the spacer block that comes with the flip kit installed so he may have swapped in a different input too :P

that looks just like the go 2 guy clocking ring i used when i done my 300 conversion. that is the stock d300 input shaft and bearting retainer.

it is going to depend on your output shaft length on your trans i think. the only problem i had was mine was 2 long and the floor was in the way.

ron4x4
11-18-2008, 06:05 PM
As I study different pictures I am noticing that the 247, I currently have has a 3/8's of an inch lip that the mounting studs come out of, which is the mounting surface. The 300 is flat so there is a small gain in length if it is needed.
I did send emails to AA and JB, about the situation, it'll be interesting to see what they say.
Also the best I have seen a d300 on Pirate4x4is $200

nierace
11-18-2008, 06:49 PM
I believe the ZJ uses the 1.55" input on the V8, the 545RFE in the WJ's is completely different.

Yeah I noticed the problem with clearing the floorboards that TJ guys were having looks like more fun :P

ron4x4
11-18-2008, 06:55 PM
Ah! I have no problem cutting the Floor Boards it that was the only issue. Hopefully JB and AA will get back to me soon
Thanks for all the input guys

Ron

ron4x4
11-18-2008, 08:06 PM
Here is the response from AA
"Does your jeep have an 45re or 545rfe? Both were available behind the
4.7L v-8 in 2001. There is no standard measurment of the output shaft
chysler installed in the trans. I have seen up to a 1" recessed to 3/4"
positive stick out. You will need to remove the factory NP tranfer case
and measure where the output shaft is in relationship with the adapter
casting. We make a longer input shaft for the dana 300 if you have a
recessed output shaft. Our clocking ring setup for the nv3550's have the
longer input with it part #50-8604. The logner input is available with
out the clocking ring also.
Steve Roberts
Advance Adapters
Tech support and Sales
1-800-350-2223 ext 526 U.S.
1-805-238-7000 ext 526 International"

So from this It looks like it could be done!

ron4x4
11-19-2008, 01:42 PM
Ron
It really does not matter which one (transmission) it is for what you are doing. We
just need to know what the output shaft length is (recessed or positive
sitck out from the factory trans adapter) Let me know and we will help
you out.
Steve Roberts
Advance Adapters
Tech support and Sales

nierace
11-19-2008, 01:54 PM
Do it up and take notes for the rest of us! :P

jgilbo17
02-16-2009, 02:19 PM
i am in the middle of swaping a dana 300 into my 97 tj with 3spd auto, there is some clearence issues with shifters but shortening the shift rails and a couple of holes in the trans have to be ovaled out to mate the trans to the t-case without a clocking ring, this takes up the space that is lost to the clock ring, i will post some pics of how im doing it,
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3649.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3647.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3661.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3654.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3655.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3670.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3672.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3672.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3674.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3681.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3680.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3679.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3683.jpg
http://i299.photobucket.com/albums/mm295/jgilbochopper/DSCF3684.jpg

jgilbo17
02-16-2009, 02:24 PM
its still not done i just have to build the sticks themselfs, a manual trans or an aw4 would have been easier, there are more pic but i cant find them

ron4x4
02-16-2009, 02:50 PM
Awesome picts, That is just the motivation I need to do mine, please if you can keep coming with the picts and descriptions as you finish the project
Thanks a ton

zjmikey
10-04-2009, 11:51 PM
Putting a D300 in a WJ is quite possibly the worst idea you could think of.

What are you expecting to gain? strength? NOPE, GEAR reduction? NOPE

Weight savings?, Definitely NOPE, Ease of Use, NOPE adaption NOPE..

Not sure why you want to put in a FLipped D300 in a WJ, Kinda like putting wagon wheels on an F1 car.

There are 100s of other choices out there that would be a better and in the long run more economical TC swap.

NP241OR from a Rubicon would be a good choice
Stax 2 speed
Atlas,
Heck, even a decked out modded 231 with wide chain kit and 5 gear planetaries would be better.

By the time you custom machine adaptors, flip kit, Low Range Kit, custom cable shifter to make it work and adapt the tail housing, Not to mention upgrading the input shaft, and output on the D300, you could easily buy any of the above cases and have alot less headaches in the long run.

ATL ZJ
10-05-2009, 12:06 AM
Mikey, what caused you to dig up this old post?

241s are overrated. I broke two in a tow rig with 30" tires. Maybe the rubi cases are better but I have never been impressed by aluminum NP/NV cases. I broke a 231 mainshaft easily with a stock 4.0 and 37" tires. 300s are ok- I think the attraction is that you get to keep stock gearing of 2.72:1 and they are fairly strong. 300s start to make sense if you are doing something like upgrading front axles at the same time. Then you could just find a chevy 60, presumably for less $ than a ford hp60, and save a few bucks and get twinsticks also.

All that said, I'm a 205/atlas/stak guy myself.