Here is my writeup on rebuilding a flipped Dana 300 with a Teralow for my TJ:

http://members.cox.net/rv6a/d300.html

Chris

nice nice...still think im gonna go w/ the Atlas though :flipoff2: :) :)

Nice right up!! I'll print this and put in the folder for future reference.
:p :p

Originally posted by Blue97TJ
Here is my writeup on rebuilding a flipped Dana 300 with a Teralow for my TJ:

http://members.cox.net/rv6a/d300.html

Chris

Ooooops, Tera Low gears + Dana 300 = :nuke:

Good luck, your gears are gona need it.
Oh ya the required pic




http://www.superford.org/registry/users/208/144/PICT0011.JPG
More pics available Here (http://www.superford.org/registry/?vID=144) Under the section called Outback Challenge 2002


EDIT: Let me add, that my post in no way was supposed to detract from the great work you did on both the Mod and write up. Good luck with your set up.

Originally posted by bronco78
Ooooops, Tera Low gears + Dana 300 = :nuke:

Good luck, your gears are gona need it.


Was that one of the older gear sets or the newer ones. Tera recognized a problem with using the D300 Teralow with some factory D300 gears so they now include all new gears in their D300 Teralow kit, not just the ones required to change the ratio.

Chris

Originally posted by Blue97TJ


Was that one of the older gear sets or the newer ones. Tera recognized a problem with using the D300 Teralow with some factory D300 gears so they now include all new gears in their D300 Teralow kit, not just the ones required to change the ratio.

Chris

about two years old, and Tera spoke well of there use in the spec'd vehicle just a few months ago. There were asked if the gears would be ok for our use and we were told yes. As you can see I guess not. If there was a problem we should have been told.

great write up..... but my current door holder is blown up 300 with the tera low kit install the only gear's left where the originals later

I see two kinds of tera low kits....the ones that were installed right and the ones that weren't. Not saying that they weren't installed right for sure......but if they are not clearanced perfect and installed w/ a full rebuild as well you can expect:nuke: :D

Originally posted by Sillyneck
I see two kinds of tera low kits....the ones that were installed right and the ones that weren't. Not saying that they weren't installed right for sure......but if they are not clearanced perfect and installed w/ a full rebuild as well you can expect:nuke: :D

Of course you are correct, if not installed correctly the best parts mean nothing...And as I did not install these gears I'll pass on that position. I will say, that the person who did the work is qualified to do it and has no problems with any other TC, trans, dif he has assembled., he works in a drive line shop and does this for a living. I've seen him work, and though I do my own gear work, if I had to, I'd let him do the setup.

I think our failure was simply a case of too much, and not enough.

Too much power
Too much traction
Not enough beef.

I will say the gears worked great behind the 4cyl, which is why they were installed in the first place. Once the 5.0 /NV4500 swap was done the Dana 300 was gone through as a precaution, it all looked and spec'd out ok, full bearing and seal kit was reinstalled, it was used in the current power train combo only a few times, maybe 5 or 6, and never in high traction areas, always mud, sand, and some dry dirt. When it failed we had both ARBs on, the 36x12.50 TSL's were aired down, we were in high traction rocks, small rock, 30 in high or so hit the right tire and spring, at maybe 2 mph forward speed. At most the motor should have stalled, I would have thought (as has happend before) the tire and spring hanger (reverse shackle) should have slid/popped over the rock.. BUT what happened is the gear teeth on the low gears stripped off, then using high range the rear output shaft twisted off. Had thought about going with an Atlas II, should have could have, might have, but did not.. But will now I think.