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Old 07-22-2003, 03:32 PM   #1 (permalink)
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$20 Dana 300 flip kit

A couple of people have been asking me for info on how I flipped my Dana 300 so here goes. First of all most of the credit has to go toward Xtremetoy here on the board because he gave me the idea on how to do it.
First of all I made a new piece to house the shift rails between the case and the original cover out of 1.5" by 3/4" rectangular tubing. I drilled it to accept the cover and the new rails. For the shift rails I used 5/8" ID pipe which is the size of the rails. I took the original front shift rod housing and cut it in half and flipped it over (so I could reuse the detents and shifters etc.) and attached it to the new shift rail housing.
Next I pulled the case apart and flipped the shift forks over to come out of the (new) top. The reverse fork has to be ground just a little to clear the forward fork. Next I drilled two new holes in the shift rods to locate the set screws, I just played with the detents and the forks until I figured out exactly where I wanted the holes, I then marked them and pulled the case apart to drill the rods. This was the hardest part of the whole thing because if the holes are off it won't go into gear all the way when you shift (obviously).
I made a new plate to cover the original shifter holes in the bottom of the case which also holds the bottom of the front output shaft bearing housing.
Since I was just going by trial and error I didn't get a lot of pics but I'll post what I have. I know the expanation kinda sucks but I'm going from memory here. Basically it took me about 14 hours total to make everything, pull the case apart and put it back together. It's really simple and works great so far. Oh, yeah, for shifters I used a couple of my old Toyota pieces. It doesn't look pretty but it gets the job done.
I'll try to answer any questions that anyone has as best as possible.

The first pic shows the top of the case and where I cut the shift housing.

Tass
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Old 07-22-2003, 03:33 PM   #2 (permalink)
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The next pic is basically the same thing. It's hard to see but it shows how close the two shift forks are.

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Old 07-22-2003, 03:35 PM   #3 (permalink)
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The next pic is the test fitting in the truck. It's behind a Toyota t-case using an OTT adapter (which is a work of art BTW)

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Old 07-22-2003, 03:41 PM   #4 (permalink)
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Next is with the top plate on and the shifters installed. Sorry the pic is blurry.

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Old 07-22-2003, 03:50 PM   #5 (permalink)
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Clean set up! So I assume the dana 300 is only a pass side drop?
Seams real easy (time excluded) to do and is a better set up than the stock dana 20s for EB's and more options for up grades.
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Old 07-22-2003, 04:00 PM   #6 (permalink)
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Looks cool. The shifters for the 300 look like toy shifters???
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Old 07-22-2003, 04:01 PM   #7 (permalink)
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Yes, stock is pass. side drop. A lot of the time was figuring stuff out like where to drill, how to attach the shifter housing etc. I'm sure I could do another one less time.

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Old 07-22-2003, 04:02 PM   #8 (permalink)
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Quote:
Originally posted by 66CJdean
Looks cool. The shifters for the 300 look like toy shifters???
They are Toy shifters. I also used the Toy shifter housings, I just cut them out of the top of some old cases I had laying around

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Old 07-22-2003, 04:13 PM   #9 (permalink)
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They make a nice pivot point and clean.
What did you do for a fill/overfill port so as to get the right amount of fluid in it?
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Old 07-22-2003, 05:28 PM   #10 (permalink)
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using a similar theory could you flip a toy t-case upside down? do you think??? im sorta confused on the issue, at first i thought it would spin the wrong way, now i wonder what i was smoking before!

does the Dana 20 have front wheel disconnect? will it hold up to the punishment? (I read bv's article but im not convinced its as good as an atlas)
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Old 07-22-2003, 06:59 PM   #11 (permalink)
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using a similar theory could you flip a toy t-case upside down? do you think??? im sorta confused on the issue, at first i thought it would spin the wrong way, now i wonder what i was smoking before!

does the Dana 20 have front wheel disconnect? will it hold up to the punishment? (I read bv's article but im not convinced its as good as an atlas)
It's a dana 300 and yes they do have front axle disconnect. hi/lo on one stick, 2wd/4wd on the other.

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Old 07-22-2003, 07:06 PM   #12 (permalink)
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Quote:
Originally posted by Damo


hi/lo on one stick, 2wd/4wd on the other.

Damo, this is DEFINITELY incorrect. The left stick is for the front axle, and the right stick is for the rear axle. With the 300 in the stock position, the sticks all the way forward is low, middle is nuetral, and rear is high.
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Old 07-22-2003, 07:08 PM   #13 (permalink)
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[QUOTE]Originally posted by 66CJdean
They make a nice pivot point and clean.
What did you do for a fill/overfill port so as to get the right amount of fluid in it?
[/QUOTE

I filled it up before I put the top on. You could use the plug on the top cover to fill it as long as you measure how much is going in.

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Old 07-22-2003, 07:13 PM   #14 (permalink)
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Originally posted by Madmarx


Damo, this is DEFINITELY incorrect. The left stick is for the front axle, and the right stick is for the rear axle. With the 300 in the stock position, the sticks all the way forward is low, middle is nuetral, and rear is high.
My bad. But I got the 300 thing right and u can nuetral the front output independant of the rear...

Ever run it with one end in hi and the other in lo?
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Old 07-22-2003, 09:12 PM   #15 (permalink)
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Nope, I never took mine apart so I could take out the interlock pill.. I imagine it would blow up pretty dang fast
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Old 07-23-2003, 05:18 AM   #16 (permalink)
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Can you make me one for $20?
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Old 07-23-2003, 05:28 AM   #17 (permalink)
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Originally posted by Damo


It's a dana 300 and yes they do have front axle disconnect. hi/lo on one stick, 2wd/4wd on the other.

And he was asking a Question about a Dana 20 not a 300
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Old 07-23-2003, 07:56 AM   #18 (permalink)
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Are there any lubrication issues or problems with flipping a D300?

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Old 07-23-2003, 10:20 AM   #19 (permalink)
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not a bad setup.
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Old 07-23-2003, 10:41 AM   #20 (permalink)
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300 Flip

Sweet!!! I'll have to remember this option when I go full size!!!
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Old 07-23-2003, 11:25 AM   #21 (permalink)
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you should seriously consider making that into some sort of "kit", or having people send you their D300 and having you modify it. The DOE kit is like $800, though I think it includes the clocking ring and stuff also...
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Old 07-23-2003, 02:15 PM   #22 (permalink)
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you should seriously consider making that into some sort of "kit", or having people send you their D300 and having you modify it. The DOE kit is like $800, though I think it includes the clocking ring and stuff also...
I can barely find time to work on my rig, let alone building things for other people

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Old 07-23-2003, 07:13 PM   #23 (permalink)
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Quote:
Originally posted by RUFF


And he was asking a Question about a Dana 20 not a 300
doesnt matter. the 20 is the same way,so same answer applies

nice job on the home-brewed flip
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Old 08-11-2003, 11:00 AM   #24 (permalink)
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have you taken this on the trail yet? how is it holding up?
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Old 08-11-2003, 11:27 AM   #25 (permalink)
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