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View Full Version : AW4 to NP203 to D300 flipped clocked twin stick and 4:1



Alaska ZJ
06-28-2004, 09:04 PM
I got this buildup idea fram MattZJ. Man I just loved following his week to week progress via pics and comments. So I am going to do the same thing with my new Tcase endevor.

I am putting a NP 203 mated to a D300 that is flipped clocked twin sticked and with a 4:1 gearset inside.

I am seriously tired of all the Toyota guys having all the good low gearing. So when I am done I will have.

Front and rear will be independant.

Gear choices in the tcases will include. 1:1, 2:1, 4:1 and 8:1

I seriously looked at an atlas and it is a great option. Reason I am not using it. Way to easy. Some guys want to wheel more than build....I like to build as much as I wheel.

I looked at a straight flipped D300. Kinda cool but you only have 1:1 and 4:1 and I am looking for the ability to run Mud and Rocks.

I looked at a Ford np205. Hella strong but there are not lower gears from it and hence I would be better with just a D300. Sure you can get 203 3:1 gears but they are spendy like WAY spendy.

I will be using Lomax 4:1 gears and probably will do a 32 spline output conversion at the same time for the 300.

So here is the start of my build. Fire away with any and all questions.

Here is what you start with for the 203. It is a Mopar New Process 203 out of a late 70's Ramcharger. It was in a wreck...that tranny adapter looks a little cracked.....

http://www.kodiakoffroad.com/images/chuggy/203.jpg

Again here is my friend Bgreen's Tech Page on the 203 and lots of 205 info as well incase someone decides to use a 205 from a ford.

Bgreen's Tcase Tech (http://www.akfabshop.com/alaskaoffroad/tech_2.htm)

Kraqa
06-29-2004, 12:01 AM
sweeeeeeet. I love to go to school. let the learning begin.

i have to do something with my t-case cause the 231 is good but it seems to leak all the time no matter what i do and i now want to run twin sticks. so this will be a good thread.

paulkeith
06-29-2004, 01:34 AM
i love how on pbb one guy will put his whole rig buildup in one 16 page long thread. keeps things simple and very easy to follow.


make it a good one, alaskazj.

Paul

Trancezj
06-29-2004, 10:34 AM
sounds great.. where are you gunna put all that though?

Alaska ZJ
06-29-2004, 12:18 PM
sounds great.. where are you gunna put all that though?

I am gonna put it in the Chuggy for now. I have a top secret build going as well but that is taking a LONG time and I will unviel it only when it is 100% and ready for it's first trail test.

Alaska ZJ
06-29-2004, 12:36 PM
Here is what I did today.

First here is a picture of the Labratory.....Gotta love my huge workspace.

http://www.kodiakoffroad.com/images/chuggy/labratory.jpg

Here are all the parts that I saved from the Dodge 203. Case and internals, Mainshaft, Input, Shift Fork, mounting bolts, Mounting plate (might be any easy mod to mount this SOB), half the 4x4 portion shift fork (for illustrative purpose) and a pair of needle bearing races (to reference for possible support bearing installation into the doubler.

http://www.kodiakoffroad.com/images/chuggy/saved%20parts.jpg

Here is what I am tossing in the recycling bin....JUNK. But for those of you who don't think that 203 is very strong because of the chain....man you must be really hard on your shit cuz that sucker is HUGE.

http://www.kodiakoffroad.com/images/chuggy/junk.jpg

I make my kids pull this around the yard. Helps them sleep at night...lol.

http://www.kodiakoffroad.com/images/chuggy/junkandsled.jpg

Here is the 203 shiftrail that controls the 4x4 operation of the Tcase. I could not for the life of me figure out how to get it out. Anyone know? Well apparently Mr. Dewalt knew.....he just cut the SOB in half.

http://www.kodiakoffroad.com/images/chuggy/203shiftrail.jpg

Here is a good shot of the Dodge 203 Input. count the splines. size is correct as well.

http://www.kodiakoffroad.com/images/chuggy/dodge203input.jpg

Here is the Index or Anti Rotation Tab. You need to either machine it off or do like me and let Mr. Milwaukee take care of it. Just make sure he is using an aluminum grinding disc. If he uses a steel grinding disc the Aluminum can plug them up and actually heat them up to the point of Exploding. Ask me how I know.

http://www.kodiakoffroad.com/images/chuggy/indextab.jpg

That is all for now.

ATL ZJ
06-29-2004, 11:59 PM
http://www.kodiakoffroad.com/images/chuggy/junkandsled.jpg


And I thought I was the only one that used a "parts sled". No action shots, but you can see it in the background of my ever-so-neat garage here:
http://img41.photobucket.com/albums/v125/atlzj/ATF.jpg

Alaska ZJ
06-30-2004, 09:05 AM
That sled of mine has quite a history. It has compacted the spinal column of a Marine, Hauled Gear behind a snowmachine at triple digit speeds, Moved gut piles around while hunting and then hauled the whatever it was that I killed home, Been on more Ice fishing trips that 95% of the people on this board have ever been fishing I bet.

Plus my kids use it daily for a bike ramp in the summer and a well sled in the winter. It is getting long in the tooth though. I am searching for a replacement but it is hard to find sleds of that quality anymore.

People call my FJ a Jeep all the time. "Nice Jeep." "were?" and then I walk away.

Trancezj
06-30-2004, 09:10 AM
I have a wheel barrow. I pile all my shit in it.

nathan
06-30-2004, 09:53 AM
I have a wheel barrow. I pile all my shit in it.

i just carry all my stuff around. i'm huuuge :mrgreen:

BigDaveZJ
06-30-2004, 09:58 AM
i'm huuuge :mrgreen:


Obviously you haven't met me or Alaska yet! 8)

Trancezj
06-30-2004, 10:13 AM
i'm huuuge :mrgreen:


Obviously you haven't met me or Alaska yet! 8)
I'm 5'10" 235. ~12%bf 8)
edit: 5'9", I keep forgeting squats shrunk my ass.

BigDaveZJ
06-30-2004, 10:30 AM
i'm huuuge :mrgreen:


Obviously you haven't met me or Alaska yet! 8)
I'm 5'10" 235. ~12%bf 8)
edit: 5'9", I keep forgeting squats shrunk my ass.

[heineken keg can commercial voice] yooouu're puny! [/voice]

6'5" 310lbs here, I wanna say Brentt said he was 6'2" 275, he's a lot more muscle than I am though.

Trancezj
06-30-2004, 10:49 AM
lol, he's a big ol' boy.

JeepinHank
06-30-2004, 01:04 PM
I'm scared to have one though, 'cause I'd prolly rage on the first person who called it a jeep.

Man, didn't you guys know? FJ = Foreign Jeep! :lol:

This may be a stupid newbie question, but I've always wondered this:

When you mate the two t-cases do you just put the two cases in line? If so am I visualizing this correctly?

AW4 (I think that's what you said you're using) to the 203 to the 300 to the drive shafts....

Do you do anything with the front d-shaft output on the 203? Is is just there and spinning, or do you remove it, divorce it (always wondered what that really meant), cap it off, what?

I just imagined that there could be a benefit to having an extra shaft spinning somewhere when you wanted it - almost like a PTO. Just put the 300 in neutral, and the 203 in 4wd (hi or lo), and you're sitting still using the engine power to turn something- Say maybe for a belt driven OBW, or I don't know a bush hog for the chuggy? :wink: I'm sure there's probably some screwed up logic or a false assumption in there somewhere, and I'm just not seeing it. Care to clarify the concept of running dual t-cases for a newb like me? Am I somewhat on the right track here, or am I way off?

Just trying to get a mental picture, since I've never seen anything like this. Heard of doing it, just never seen it. :?

H

jwbronco
06-30-2004, 03:13 PM
There's a few other options too other than a dana 300. Do they actually make an adapter for the 203 to mount up to our tranmissions? I guess you'll have more of a chance, I have the darn 45re. If the adapter exist for the 203 you could mount a dana 20 to that and get the 3.15 gears for it. They also sell 4.86 gears for the dana 20 in a early bronco which would have a driver side drop. On top of that they sell a dual dana 20 setup with the lower part of the first 20 cut off called a Cold Duck from wildhorses. I would rather have a dana 20 over a 300 but thats because I want a bronco part in my jeep so bad.


http://www.wildhorses4x4.com/34.asp

Good Tech
http://www.geocities.com/yj3qtr_ton/2transfercase.html

Alaska ZJ
06-30-2004, 04:19 PM
Hank- You only use the front part of the NP203. This is called the range box. It is the part that shifts from high to low 1:1 to 2:1 in the case of the NP203.

You do not use ANY of the NP203 ouputs.

You have the Mainshaft (That big ol gear looking thing sitting on the bench) of the NP203 machined down to match the Input of the second tcase.

Then you use this to bolt both Tcases together.

http://www.wagonermachine.com/dualcase-2.jpg

The Second Tcase bolts right up like it would in a stock configuration (except in my case, it will be upside down and kinda crooked)

Advantages to this....Streangth. You break this setup and your an idiot. Gearing selection, when I am done I will have 1:1, 2:1, 4:1 and 8:1. Along with Front Wheel Drive, Rear Wheel Drive and Four Wheel Drive.

This setup is stronger and cheaper than an Atlas. Plus it has a SHITload of flexibility. I want to wheel Rocks, Mud, Highway, Sand and everything in between. This setup gives me those options.

This is just the sort of Newbie question that this board was created for....Thank YOU!

jwbronco- I am not going to unviel the tranny mount system. But your gonna kick yourself in the nuts when you see how simple it is....

As for my size....Who Cares, I bet I could kick your ass or I know someone that will do it for me....lol

Trancezj
06-30-2004, 04:28 PM
lol, you wanna fight? j/k. Looks like a good set up bro.

JeepinHank
06-30-2004, 04:47 PM
:idea: I think i just had one of those epiphany thingies... :idea:

J-dub, Alaska - that's just what I needed - all clear now! It seems I've got a bit of reading to do. So the biggest advantage of this over an atlas, klune, or something similar would be cost and the variety of gear combinations?

jwbronco
06-30-2004, 05:29 PM
jwbronco- I am not going to unviel the tranny mount system. But your gonna kick yourself in the nuts when you see how simple it is....


I'm assuming that you'd use a dodge 203 because they use a 23 spline female input like the 231, 242, 247, and 249. I really wish I could go outside and look but can't do that from dust valley. I also wish I had more than one vehicle because my jeep would be so much further along or complete till i found another modification I'd like to do.

What kind of modifications would have to be done to the input? I realize the spline is the same but we have to change parts in the various transfercase to make them up.

Next question, what would be a better match a dana 300 or a dana 20 from a early bronco? I'm pretty sure that a decked out 300 would be stronger but the dana 20 is pretty stout especially with the 32 spline output. I think one main advantage to a 20 would be that you wouldn't need to buy a kit to get the output to comeout on the driverside and it is a bit shorter. If I did the 203/20 I would put the 3.15 gears in the 20 and have good range of selections for gears. The only thing that I haven't figured out would be the speedometer for the bronco 20 because I will have to use a TJ style speedo because I have to eliminate the tone rings. I already have the 5 volt powersupply that I built for that purpose.

http://www.high-impact.net/transmission_and_gear/Klune-V_Bronco_D20_combo.htm

http://www.high-impact.net/transmission_and_gear/Tcase_Dana20EarlyBronco.htm

you can use that link to navigate for information on other transfercases

Alaska ZJ
06-30-2004, 10:16 PM
Flipping the 300 is only a matter of having the bolt holes for the adapter drilled 180 out of stock.

I also think the 300 is a better option. 3.whatever:1 is to close to 2:1 for my taste. I want to spread the gear ratio out and 4:1 is better for my taste.

But I am sure you could easily put the 20 on an adapter just fine.

The 300 has a 32 spline output upgrade as well.....Plus it is in every Jeep since the early 70's until the late 80's.

Read my first post about the inputs....shoot you can even count the splines if your up to it.

Kraqa
07-01-2004, 01:34 AM
man i love this board. Never had the whole duel t-case thing cleared up for me. thanx alaska.

Alaska ZJ
07-01-2004, 09:02 AM
man i love this board. Never had the whole duel t-case thing cleared up for me. thanx alaska.

No problem, this is the kind of stuff that the NAGCA board was meant to have as well. And I wanted to post it, but it would just get burried in the plethora af Crack Ho postings. (yes I used a 3 dollar word and Crack Ho in the same sentance....can you hear the banjo?)

nmzj
07-01-2004, 10:26 AM
http://www.akfabshop.com/alaskaoffroad/images/Tech/Tcase/toomanyshifters.jpg

I'm already lost. LOL I'm trying to digest this. I need some sort of x-fer case for the buggy...this may be a viable solution.

Thanks Brentt, you are a wealth of info (useless or otherwise :lol: )

FinlayZJ
07-01-2004, 11:11 AM
Alaska..........as long as you have that avatar you can assume no one will be reading your posts. I saw a bunch of random letters in your post out of the corner of my eye. My attention was focused to the left of screen.

:shock:

Alaska ZJ
07-01-2004, 02:53 PM
http://www.akfabshop.com/alaskaoffroad/images/Tech/Tcase/toomanyshifters.jpg

I'm already lost. LOL I'm trying to digest this. I need some sort of x-fer case for the buggy...this may be a viable solution.

Thanks Brentt, you are a wealth of info (useless or otherwise :lol: )

Ok let me explain that picture. First those nobs are hand crafted out of 6061....Bgreen is the high heat with details like this.

We will start with the Farthest away shifter and work toward the closest.

Shifter 1- This controls the NP 203 Transfercase range box. It has 3 positions. 1:1, Nuetral and 2:1


Shifter 2- Transmission. This works just like any other transmission shifter. In this case it is a th400 with a reverse valve body and compression braking in all three forward gears (Special Valve Body)

Shifter 3- This controls the front axle output. In this case it is a NP205 and has 3 positions as well. 1:1, Nuetral and 2:1

Shifter 4- This controls the Rear axle output of the NP205. Again 1:1, Nuetral and 2:1

Now lets just forget about the tranny for right now. It doesn't work like your normal Auto tranny but that is another entire topic of conversation.

For the Tcase you can mix and match Gear Ranges from the NP203 and the NP205. So for instance you can have the NP203 in 2:1 and the NP205 Front output in 2:1 with the rear output in Nuetral. This would give you a 4:1 Front Wheel Drive Vehicle.

That would really kick ass for that little waterhole right before the waterfall on Poison spider.

This is a great option for you Jason. Your timeline is not tight since your making a buggy, It gives you WAY more options than an Atlas. It is stronger than an Atlas and it just cool. If at a later date you want to put it in the CJ8 you can....It still has 1:1 for highway use.

As for my avatar. If it is a distraction I will remove it.....Personally I figure that she paid good money for those honkers and should be able to share them with ALL!

Cody
07-01-2004, 06:28 PM
That thing is going to weigh a ton and if it's not well supported, could cause ugly failures up the line. I've seen a couple buggies with poorly engineered t-case supports that have resulted in cracked tranny housings. I trust that it will be supported though.

The only down side to my rig now, is that it sucks in the sand. In high range, I power out on climbs before I can launch off the top, in low range I'm turning 5000 rpm's and going nowhere. a 2:1 or 2.5:1 would be way bitchen for something like that.

Cody

So when is the thread where you add a front locker so you can actually get to trails where front or rear digs would help you? :D

BigDaveZJ
07-01-2004, 07:05 PM
So when is the thread where you add a front locker so you can actually get to trails where front or rear digs would help you? :D


:twisted:

GetoZJ
07-01-2004, 07:36 PM
i'm huuuge :mrgreen:


Obviously you haven't met me or Alaska yet! 8)

Obviously you haven't met Nathan yet, he's fawkin' giant :shock:

Alaska ZJ
07-01-2004, 10:12 PM
Weight. Yes it is a concern if it is just hanging out there. This will not be.

The 203 and 300 will both have mounts and the Engine is getting a new design as well.

jwbronco
07-02-2004, 10:36 AM
I found this very informative site for a 203/20 combo. Thought I'd pass it along. Alaska keep the great pics coming!!!

http://www.rightcoastcrawler.com/LloydC/tech/TrannyProject.html

Alaska ZJ
07-11-2004, 03:07 PM
Update.

To make this sucker mount up to the AW4 like I wantI have to drill and tap some new holes. Not a big deal. BUT you have to take the Idler gear (or more appropriately named Countershaft and gears)

http://www.kodiakoffroad.com/images/chuggy/idlershaft1.jpg

The above picture is the Transmission side of the 203.

http://www.kodiakoffroad.com/images/chuggy/idlershaft2.jpg

This is the idlershaft that is on the 4x4 side of the 203. You want to pound out the shaft from this side. On a scale of 1-10 with 10 requiring 2 hands and a 5+ pound hammer, this mother took a 8 to get out.

http://www.kodiakoffroad.com/images/chuggy/needlebearings.jpg

These are the Needle Bearings that are going to be expelled during the removal of the shaft. Make sure you don't lose any.

http://www.kodiakoffroad.com/images/chuggy/countershaft.jpg

That is the countershaft removed with all it's little parts. Here is the order in which they are installed, starting at the tranny side of the case. Odd Shaped Keeper, Thin Washer, Needle bearings, Thick spacer, Needle bearings, Thin washer, Needle bearings Thin washer, Odd shaped keeper. I will go over assembly when I get that far in the build.

http://www.kodiakoffroad.com/images/chuggy/paintprep1.jpg

All prepped for paint.

http://www.kodiakoffroad.com/images/chuggy/painted1.jpg

Painted.

More later.

nmzj
07-12-2004, 12:42 PM
Brentt, looking good. Is this going in the Chuggy? I'm curious to see your crossmember(s)...

Jason

nmzj
07-13-2004, 11:50 AM
Also Brentt, I've tried to find this WMS adaptor. You have a link or source?

Jason

Alaska ZJ
07-13-2004, 01:42 PM
Get the stazworks doubler. 250 bucks less and basically the same shit.

http://www.stazworks.com/doublers.html

OverkillZJ
07-13-2004, 09:15 PM
Brennt, looking good! I can't wait to see the end result, as well as how much floorboard you have to cut to get the levers up inside.

Well, that's assuming the Chuggy still has floorboards :wink:

Matt

Alaska ZJ
07-13-2004, 11:20 PM
Floorboards are for pussies

OverkillZJ
07-14-2004, 01:01 AM
Floorboards are for pussies

So are automatics, but I believe the chuggy still has one at the moment anyway 8)

Alaska ZJ
07-18-2004, 01:47 PM
Update Time.

I dropped the 242 (it is FOR SALE). This is what the AW4 ouput looks like.

http://www.kodiakoffroad.com/images/chuggy/aw4output.jpg

So just to make absolute sure shit was going to jive I test fit the Dodge 203 input onto the AW4 output. Fits perfect. You will not need any new seals or anything. I had heard rumors that a 1/8 spacer would be required. I don't think it will be but it's not that big of a deal if it is.

http://www.kodiakoffroad.com/images/chuggy/203inputtest.jpg

Here is the 203 box mocked up on the AW4. I wanted to check shifter clearences and decide if I wanted a Ford or Chevy D60. I made my selection and decided on a Ford. It will not require near as much floor modification. I wasn't really looking for a Flat belly, just a smooth belly.

The picture is at a odd angle but the bottom of the 203 is 3/4 of an inch above the bottom edge of the cross member. I will mess with it some more when I get ready to drill the holes for the circular mount.

http://www.kodiakoffroad.com/images/chuggy/203aw4ford.jpg

Here is my shifter clearence on the passenger side for the 203.

http://www.kodiakoffroad.com/images/chuggy/203aw4fordshifter.jpg

That is all for now.

Alaska ZJ
07-19-2004, 05:10 PM
Here is the Deceleraometer for the airbag.

http://www.kodiakoffroad.com/images/chuggy/airbagmodule.jpg

Here is the Floor all opened up and prepared for surgery. I love cutting shit.

http://www.kodiakoffroad.com/images/chuggy/readyforsurgery.jpg

Yesterday as I was proofing my post (not for spelling just making sure all the shit worked) I read through my 203 portion and noticed that I was indeed compramising on not having a flat belly on this thing. So I said "fuck it" and cut the floor.

Here is the 203 flipped upside down. It now sits about 1 inch lower than the Tranny housing. A gain of probably 6 inches over the stock setup.

Another benefit to this is that I am going to be able to use the Stock 242 linkage to be able to shift the 203 into high and low. SWEET.

http://www.kodiakoffroad.com/images/chuggy/203clocked180.jpg

There is one downfall though. I am going to lose my cup holders in the middle.

http://www.kodiakoffroad.com/images/chuggy/203clockedfloor.jpg

That is all for today folks.

FinlayZJ
07-19-2004, 05:17 PM
No cup holders? How are you going to carry your mocha latte when you go jean shopping at the Gap?



With the t-case flipped like that, are you going to have any oiling problems?

Alaska ZJ
07-19-2004, 11:04 PM
No oiling problems. It is a gear driven case. Just have to make a new fill and new drain hole.

Alaska ZJ
09-08-2004, 06:09 PM
Update time.

First here is a picture of the 203 output shaft prior to it's machining and splining to fit the new D300. It will be cut down about 4 inches and splined in the 23 spline variety to match the 300.

One kinda cool thing about doing it this way is that in a pinch I could through the 203 out of the mix and put the 300 straight to the AW4. Would have to manually shift it and would have to do some tricky driveline making (Can you say reciever tubing) but it could work.

http://www.kodiakoffroad.com/images/chuggy/outgoingshaft.jpg

Next kinda tricky thing is to transfer the round Jeep Pattern to the Dodge 203 Case.

Lucky for us that 203 case is really thick and beefy. So drilling and tapping the case is not a big deal and pleanty strong.

But how do you make sure all the shit lines up correctly? Well you get yourself a set of these from Harbor Frieght. They are called Transfer Punches. There are really expensive sets out there for super high precision but WTF...this baby ain't going to the moon. 15 bucks and I am stransfering the center holes like a seasoned machinest.

http://www.kodiakoffroad.com/images/chuggy/transferpunches3.jpg

fuzzy close up.

http://www.kodiakoffroad.com/images/chuggy/transferpunches.jpg

This is a "dramatization" of how they work. They fit snugly in the hole that you are wanting to transfer. The little point is machined into the center of the given punch. Allowing you to tap a center mark onto the new surface.

Main thing is to make sure the pieces don't move in relation to eachother. A pair of ratchet straps hald everything snug enough for government work.

http://www.kodiakoffroad.com/images/chuggy/transferpunches2.jpg

Well then you take a 5/16 drillbit and drill a hole perpendicular to the case face. Using the marks you make and a Cobalt bit (I just like using these to cut) it is a breeze in the drill press.

Then take your 3/8-16 NC tap and thread the holes. A word to the wise here. Just spend the money on a high dollar high quality Tap and Tap Handle. I at first bought a cheap ass Mibro set from TSC and that fuckin thing suck in a BIG way. I then went to the $$ tool store and bought a handle and tap from Irwin. They alone were half the price of the entire Mibro kit but I broke the mibro stuff on the first hole and the Irwin stuff finished the job with ease.

http://www.kodiakoffroad.com/images/chuggy/transferedpattern.jpg

More to come as I try to put this SOB back together.

Kraqa
09-08-2004, 07:50 PM
sweeeeeeet.........

Alaska ZJ
09-09-2004, 06:47 PM
Another update.

I put the 203 range box back together. Pretty easy. Just use lots of wheel bearing grease to hold all the needle bearing for the Countershaft assembly.

Here is a exploded view diagram for the 203. It is big for a reason.

If you print it out do it in Landscape and you will get all of the range box that you will need.

http://medusa.ih8mud.com/NP205/NP203diagram.jpg

Now I am once again waiting for parts.

Alaska ZJ
09-17-2004, 06:37 PM
What I did the last couple days.

I put the 203 together via the above diagram.

Then I built this bracket. It adapts the NP203 in the 180 clocked position to the stock ZJ transfercase linkage. Now I can use the stock shifter to shift the 203 range box from high to low. That makes installation Uber Clean.

http://www.kodiakoffroad.com/images/chuggy/linkage.jpg

yes I painted it blue. I don't want it to clash with what is left of my hood.

Kraqa
09-27-2004, 11:23 PM
thats good progress.
hey i found a line on a D-300 and a ford 205. how does the rang box differ from the 205 to the 203? do you know any sort of reliability on the 205?

Alaska ZJ
09-28-2004, 10:10 AM
not sure how the 205 splits.....but I know it is a STOUT tcase.

You should be able to find a 203 and swap the guy for that 205 if it turns out to be a PIA. The ford 205 (specially with the big outputs) are rare and usually pretty spendy.

Kraqa
09-28-2004, 11:14 AM
ya the U-joints are freekin huge on the t-case, don't know the exact size..yet but i will find out. the tail shaft of the 231 i have bothers me and i don't want to spend the money on a SYE for it. so i'm definatly going for the D300 but thinking about the 203 range box as well. i mean since i'm down there i might as well right?

Alaska ZJ
09-28-2004, 06:03 PM
As long as your not afraid to cut your floor like I did.

Kraqa
09-29-2004, 01:40 AM
floors are for pussy's who can't handle a draft.





actually i would just cover up the whole and then make a new console. its just that the tail shaft really bothers me. if i broke it the case would be worthless unless unless you want to do a SYE on it if not then it would be cheeper for someone to go bye another one. and i knwo someone with a d300 and he wants to swap me for my 231. it going in another zj so the output shaft is already swapped for him.

Alaska ZJ
09-29-2004, 09:28 AM
Same reason I started this swap. SYE on the 231 is dumb as fuck when your putting in a D60 front and D70 rear. I want a 1350 CV and the D300 has that option.

I thought about an atlas....Easy and would surely do the trick. BUt it has no "wow" factor and is one dimensional (High or Low, nothing more). Price is not a concern as this doubler setup will be more than a Atlas when I am done.

Plus eventually I will get rid of the Chuggy body ans swap it over to something else.

Kraqa
09-29-2004, 10:23 AM
ya this super top secret vehicle. i think i knwo what it is. http://img.photobucket.com/albums/v280/Kraqa/thefinger.gif


ya i'm not sure if i will do a 203 to d300 or just the d300. but when i think about it when your down there you might aswell just do it right.

Alaska ZJ
09-30-2004, 09:28 AM
ya this super top secret vehicle. i think i knwo what it is. http://img.photobucket.com/albums/v280/Kraqa/thefinger.gif


Go ahead and guess. I will bet you the cost of that 203/300 adapter that you get it wrong..... :shock:

Kraqa
09-30-2004, 08:04 PM
red ZJ???????

Alaska ZJ
10-01-2004, 09:33 AM
Wrong.

Please send $550 (US) to Brentt Blair, 162-2 Delta Drive, MAFB, ND 58704.

Kraqa
10-02-2004, 04:27 AM
Shit. well hurry up man. i wana see this thing what ever it is. i know it'll be sweet.

OverkillZJ
10-02-2004, 12:45 PM
I just like the blue bracket....

gearhead313
10-18-2004, 03:34 PM
any updates? I finally got time to sit and read this thread and its definitly something i can barely grasp hold of. Can't wait to get a trip report!

Jim311
10-19-2004, 11:17 AM
any updates? I finally got time to sit and read this thread and its definitly something i can barely grasp hold of. Can't wait to get a trip report!

Ha.. join the club. I wouldn't want to lose my floor anyway :D



Plus all those knobs would confuse me :lol:

speedmontzj
10-19-2004, 02:12 PM
alaska, what color blue would that be? :)

OverkillZJ
10-19-2004, 02:52 PM
alaska, what color blue would that be? :)

that's gotta be baby blue!

speedmontzj
10-19-2004, 04:52 PM
im thinking chrysler blue.

Alaska ZJ
10-20-2004, 08:12 PM
It is Mopar Blue......

I am back from Tahoe. I rented a Jeep and ran Ellis Lake...Fun trail.

No real updates. I am going to tear apart the 300 tomarrow or the next day to get ready for the Lomax gears, 32 spline outputs and twin sticks.

Kraqa
10-31-2004, 05:47 PM
so 5 pages and its still not complete?? alaska man i'm on the edge of my seat here.

Alaska ZJ
10-31-2004, 07:05 PM
Tell John Dalton in Black River Falls Wisconsin your anxious. He is the one splining my shaft.....lol. Soon as I get that I will have a update.

Alaska ZJ
11-01-2004, 06:08 PM
Looky Looky.

http://www.kodiakoffroad.com/images/chuggy/goodies.jpg

This guy does a AWESOME job. I will gladly put this up against the ORD and WMS doublers.

http://www.kodiakoffroad.com/images/chuggy/doubler1.jpg

http://www.kodiakoffroad.com/images/chuggy/jeds.jpg

Kodiak Off Road also now has an account here and will gladly help you order one to your specification. sales@kodiakoffroad.com....

Detailed color instructions, awesome turn around time...and Will save you a bundle of cash over those other doublers.

The one pictured is not welded since I will be doing a custom rotation on this setup.

ENJOY!

Alaska ZJ
11-02-2004, 10:23 AM
Here is the 300 portion. BEEFY, and well designed.

http://www.kodiakoffroad.com/images/chuggy/300ring.jpg

Another

http://www.kodiakoffroad.com/images/chuggy/300ring2.jpg

OverkillZJ
11-02-2004, 10:29 AM
...That is a nice piece...

gearhead313
11-02-2004, 04:15 PM
...That is a nice piece...

wooh.. x2

happy
11-02-2004, 11:09 PM
did u invent the transfer case?

Kraqa
11-03-2004, 01:51 AM
...That is a nice piece...

wooh.. x2


technically wouldn't that be a whoo-whoo??

[bub-rub]whooo whooooooo[/bub-rub]

Alaska ZJ
11-03-2004, 09:14 AM
did u invent the transfer case?

No I did not invent the transfercase. I am only 30 for crying out loud.....


Thanks for the bub-rub.....

Alaska ZJ
11-03-2004, 09:01 PM
Time to weld up the doubler. I test fit everything and marked were I wanted the 300 clocked to.

Then I did this. Set the temp on the stove to 550.

http://www.kodiakoffroad.com/images/chuggy/temp.jpg

Then I inserted the parts. This is actually a picture of the "post" heat. But it was the same for the "pre" heat.

http://www.kodiakoffroad.com/images/chuggy/bakedgoods.jpg

Then we take it to my "indoor" Labratory. Man I am a Hillbilly...and I have a GREAT wife.

http://www.kodiakoffroad.com/images/chuggy/indoorlab.jpg

Then you need to put the output assembly back together. Refer to the blow up if your as dumb as I am.....

http://www.kodiakoffroad.com/images/chuggy/outputassembly.jpg

Then you need to put it all together on the 203 side.

http://www.kodiakoffroad.com/images/chuggy/203doubler.jpg

More later.

Hurricane 4x4
11-30-2004, 09:41 PM
you're the man

Kraqa
12-03-2004, 01:42 PM
can't wait.

for this thread were going to need the "2001 space odissy" theme music for the finish. http://img.photobucket.com/albums/v280/Kraqa/thefinger.gif

Alaska ZJ
12-03-2004, 02:39 PM
lol, If I would just win the damn lotto (aka Convince the wife to let me have my sack back....) I would be done already......

canadian_driver
10-17-2006, 08:19 PM
how are u flipping the 300?

gonecheenin
10-18-2006, 08:23 AM
I got a better question, have you ever finished flipping the 300?

MUDDTRACKS
10-18-2006, 08:34 AM
holy 2 years ago batman:smt017

canadian_driver
10-18-2006, 10:39 AM
yep, relized that, but with the search i couldnt find anything more recent on fliping a dana300

gonecheenin
10-18-2006, 02:44 PM
holy 2 years ago batman:smt017


Seen that, but i figured since the thread had already been brought back, and the write up was never quite finished maybe he'd have some use & abuse comments on it :-D