I`m getting ready to build a flipped D300 for my Comanche and was also going to do a complete rebuild of the case. I have never been in a t-case before so I was wondering were I could find some good info on the rebuild besides the eploded view, I`m sure I can figure it out as I go but would rather go in a little more informed. Such as are there any special tools that I will need ? Are there any adjustments or set up required for the gears ? Any info would be helpfull. And I know, I should just get an Atlas, right.:D

Factory Service manual is pretty helpful. I have my D300 in parts right now doing the teralow and output shaft upgrade. Its been real easy to work on so far except for the shift forks. :rasta:

Originally posted by Rob Kosinski
Factory Service manual is pretty helpful. I have my D300 in parts right now doing the teralow and output shaft upgrade. Its been real easy to work on so far except for the shift forks. :rasta:

Do you know if you need a different output shaft to run a C/V driveline or if you can use the stock output....are you doing it[new shaft] just for strength?

I just picked up a dana 300 rebuild kit for $108 at Bayshore truck in Fresno, all bearings and gaskets.

I just did this and did a writeup on it. This might help you:

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

Chris

In reply to websurfshop, you don't need to change your output shaft just the yoke. I just threw my box away or I would leave you the part #.

When you do it, you need to make sure that you put the correct shims back where they came from. The gears in the t-case are just like a ring and pinion in that they need the correct backlash and those shims are what make it so. The shift forks and free needle bearings are the biggest bitch of the whole process. I had to weld an allen wrench to a longer t-handle that I made out of small round bar to undo the retaining studs from the forks.

J. J.

I am doing the tera kit for additional strength. The tera kit comes with a CV rear yoke. If you need a yoke to run a CV shaft pull one off the front of a 231 or 242. :rasta:

Originally posted by Rob Kosinski
I am doing the tera kit for additional strength. The tera kit comes with a CV rear yoke. If you need a yoke to run a CV shaft pull one off the front of a 231 or 242. :rasta:

That doesn't work. Output on the 242 is way fatter than the stock 300 shaft.
You will need a
(12) Quadra-Trac Front Output Shaft Yoke, CJ7, 1976-79
Product Number: 244061X

10 spline. For Quadra-Trac Transfer Case with automatic transmission.

$59.95
From 4Wheeldrive Hardware, or anywhere else that sells them.
By the way that product number is not the Spicer part number, it's the 4wd hardware part number, it is a Spicer though.
It will also work if you want to do a CV shaft on the front.

This article should be helpfull ... ;)

http://members.cox.net/rv6a/d300rebuild.html

Originally posted by robobx


By the way that product number is not the Spicer part number, it's the 4wd hardware part number, it is a Spicer though.
It will also work if you want to do a CV shaft on the front.

Usually, if you take the front "2" off the 4WD Hardware stock number the rest actually is the Spicer number ...

Excellent writeup and with pics!! :D Should be very useful for me when I do swap one into my Cherokee.

2-4-4341 is the Spicer part #

I have a rear CV yoke for a D300 that I'll sell. PM me if interrested.

J. J.

Thanks for the great info Chris. I just came in from tearing down my donor case, turned out to be pretty easy. I don`t look forward to putting the needle bearing back though.

Originally posted by Grndhog
Thanks for the great info Chris. I just came in from tearing down my donor case, turned out to be pretty easy. I don`t look forward to putting the needle bearing back though.

Look at my rebuild page. Putting them back in was a breeze. Just use some thick grease.

Chris