Dana 300 4:1 rear low pops out of gear - Pirate4x4.Com : 4x4 and Off-Road Forum

crandall · 07-20-2007, 11:02 PM

I have a flipped Dana 300 with Terra Low 4:1 gears and Down East Offroad flip twin stick kit in my YJ. My rear drive pops out of gear OFTEN when not under load. Has anyone else had this problem?

Any advise on how to fix would be great.

Thanks,

Chris

350TBI · 07-21-2007, 06:38 AM

no

jeepint · 07-21-2007, 11:59 AM

that's the problem everyone gets with the flipped 300

KiGrind · 07-21-2007, 12:36 PM

Contact the guy that sold you the flip kit and ask them why they no tell you about little grimlins that come with the adaptor that keep crackin up your gears.

crandall · 07-21-2007, 08:16 PM

Quote:

Originally Posted by KiGrind

Contact the guy that sold you the flip kit and ask them why they no tell you about little grimlins that come with the adaptor that keep crackin up your gears.

Cool, I will email Down East Offroad products. Thanks

KiGrind · 07-21-2007, 08:30 PM

On a serious note, really just contact them and see what they do about the issue. They should know what you are talking about. If not, ask AA or Novak. Tell them you got there ring so they are extra nice to you.

Novak always handles the questions great no matter what so I'd try them first. Should be the only email you'll have to make.

crandall · 07-22-2007, 11:54 AM

I agree Novak has great customer service. I ordered a couple of clocking rings from them and when I had questions they were eager to help. I will email them too. Thanks

tinyj9 · 07-22-2007, 01:26 PM

I have te same problem with mine but mine is not flipped

crandall · 07-23-2007, 03:17 PM

I emailed D.E.O. and Novak. Hopefully I will get good news soon. Someone else told JB sells stronger detent spring kits, anyone tried them?

msalaba · 07-23-2007, 06:59 PM

I put the Tera Lo 20 kit in my Dana 20. I left out the shift interlock for the rear so I could shift both front and rear independently. Not such a good idea. Mine pops out of Rear low or high. My solution is a bungee cord and a coat hanger. Works flawlessly.....

Some day I will correst the problem properly...

KiGrind · 07-23-2007, 08:03 PM

Quote:

Originally Posted by msalaba

I put the Tera Lo 20 kit in my Dana 20. I left out the shift interlock for the rear so I could shift both front and rear independently. Not such a good idea. Mine pops out of Rear low or high. My solution is a bungee cord and a coat hanger. Works flawlessly.....

Some day I will correst the problem properly...

Offtopic.. but where did you get your d20 kit? I just know Tera makes a kit but for how much I use it. I'm planning on getting a T18 from a guy near me really soon and don't really abuse my shit as muhc as I would like and wont see anything over 35s with that case.

crandall · 07-25-2007, 06:53 PM

I wanted to post the email response from Down East Offroad Inc. Hopefully this information can help the others in the field with the same problem:

Chris, I am familar with your complaint. What we have found is no matter whether the 300 is flipped or not, it is the twin sticks that cause this condition to surface.
The springs work in tandam with a single stick design. Twin stick they are forced to handle there on pressure. The problem comes from the slide collars inside the case.
When they get some wear on them, they have a tendacy to walk themselves down the shaft and work the shifter into neutral. Some people have fixed them by putting an even stronger spring to hold them in, but the true problem is the shift collars that the shift forks sit in. An Atlas with lots of use on it can do the same thing.
Also make sure that the detent balls are fully sitting down inside the shift rail.
I hope this helps, Let me know if i can help you anymore.
Thanks
Robert Bass
Down East Offroad Inc.

ld50 · 07-25-2007, 07:26 PM

look for stronger detent spring it should take care of that, altough a pita to install

tinyj9 · 07-26-2007, 11:42 AM

where can you get the stronger springs and detents

crandall · 07-26-2007, 01:45 PM

Quote:

Originally Posted by tinyj9

where can you get the stronger springs and detents

Thats what I was wondering. I emailed Robert Bass with DEO asking him that very question. Maybe they sell them. I will post up as soon as I get a response. Unless anyone else knows....

ld50 · 07-26-2007, 01:49 PM

try JBConversions

crandall · 07-26-2007, 01:52 PM

Quote:

Originally Posted by tinyj9

where can you get the stronger springs and detents

Here is a response I got on jeepforum regarding where to find stronger springs and detents:

call JB conversions and get the stronger detents and pills. $25
the other option is to remove your shift rails and gring the notches deeper.
I don't have a 4 to 1 kit but jb said that if I find it popping out with the twin stick
to get the detent kit and that should fix it.

-I am gonna call them now

GoldToyBox · 07-26-2007, 03:22 PM

Quote:

Originally Posted by crandall

I emailed D.E.O. and Novak. Hopefully I will get good news soon. Someone else told JB sells stronger detent spring kits, anyone tried them?

I have:
Non flipped Dana 300 with Tera Low 4/1 with the JB spring kits & twin sticks
Still pops out of gear when going down hill using the "gears to hold me back" (first gear low range). It can scare the pucky out of you!

Someone posted up a mod to the shift rail .... never heard how well it worked.

crandall · 07-30-2007, 06:38 AM

Quote:

Originally Posted by GoldToyBox

I have:
Non flipped Dana 300 with Tera Low 4/1 with the JB spring kits & twin sticks
Still pops out of gear when going down hill using the "gears to hold me back" (first gear low range). It can scare the pucky out of you!

Someone posted up a mod to the shift rail .... never heard how well it worked.

I spoke to someone at JB last Friday. He told me that I could put more tension on the detent spring by spacing it out with a ball bearing the same size as the spring diameter. He said that I could buy a ball from my local hardware store. He said I would get the same results from the cheap ball bearing as I would by purchasing a stronger spring. The next step is just dropping the T-case again. I am sick of bench pressing that thing in and out.

ld50 · 07-30-2007, 07:33 AM

From what I remember, putting the stock springs back in was not too easy, cant imagine those things compressing enough to allow room for two bearings in there... I think I would try taking a little of the slope off of the shift rod with a small grinder. just an idea

gr8whytyj · 07-30-2007, 09:30 AM

When I first flipped mine I had springs in the shifters that were way too stiff made it tough to shift. I had 2 springs, 1 smaller one inside the slightly larger one. I pulled the smaller one out and the case shifted much better, but then the popping out of gear problem came about. I think I will try the bungy cord and coat hanger for a while until I need to drop the trans or case for any other reason. Thanks, Jake.

crandall · 07-31-2007, 06:40 AM

Quote:

Originally Posted by gr8whytyj

When I first flipped mine I had springs in the shifters that were way too stiff made it tough to shift. I had 2 springs, 1 smaller one inside the slightly larger one. I pulled the smaller one out and the case shifted much better, but then the popping out of gear problem came about. I think I will try the bungy cord and coat hanger for a while until I need to drop the trans or case for any other reason. Thanks, Jake.

Yup I think I will also try the bungee cord method for easy temp fix. Maybe it will get me by until it cools down and I am motivated to pull it. Then I will surely fix it right.

07-20-2007, 11:02 PM	#1 (permalink)
crandall Registered User Join Date: Feb 2007 Member # 86742 Location: Lincoln, CA 95648 Posts: 127	Dana 300 4:1 rear low pops out of gear I have a flipped Dana 300 with Terra Low 4:1 gears and Down East Offroad flip twin stick kit in my YJ. My rear drive pops out of gear OFTEN when not under load. Has anyone else had this problem? Any advise on how to fix would be great. Thanks, Chris Last edited by crandall; 07-20-2007 at 11:08 PM.

07-21-2007, 06:38 AM	#2 (permalink)
350TBI Registered User Join Date: Apr 2005 Member # 46327 Location: Boulder Tweek, Santa Cruz County Posts: 111	no __________________ 1970 (what's left of it) CJ5 SBC 350 TBI (Stock); 4L60 Dana 300 4:1.....under construction.

07-21-2007, 11:59 AM	#3 (permalink)
jeepint Registered User Join Date: Jul 2004 Member # 33212 Location: sac, ca Posts: 366	that's the problem everyone gets with the flipped 300 __________________ 91 yj, klune/205, 60 f/r, 4.88, arb, h1, 38.5 sx,

07-23-2007, 06:59 PM	#10 (permalink)
msalaba Registered User Join Date: Mar 2006 Member # 69827 Location: Minnesota Posts: 84	I put the Tera Lo 20 kit in my Dana 20. I left out the shift interlock for the rear so I could shift both front and rear independently. Not such a good idea. Mine pops out of Rear low or high. My solution is a bungee cord and a coat hanger. Works flawlessly..... Some day I will correst the problem properly... __________________ It's a Jeep Thing - No one understands!

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07-21-2007, 12:36 PM	#4 (permalink)
KiGrind Registered User Join Date: Feb 2006 Member # 66647 Location: Knoxville, TN Posts: 1,333	Contact the guy that sold you the flip kit and ask them why they no tell you about little grimlins that come with the adaptor that keep crackin up your gears.

07-21-2007, 08:30 PM	#6 (permalink)
KiGrind Registered User Join Date: Feb 2006 Member # 66647 Location: Knoxville, TN Posts: 1,333	On a serious note, really just contact them and see what they do about the issue. They should know what you are talking about. If not, ask AA or Novak. Tell them you got there ring so they are extra nice to you. Novak always handles the questions great no matter what so I'd try them first. Should be the only email you'll have to make.

07-22-2007, 11:54 AM	#7 (permalink)
crandall Registered User Join Date: Feb 2007 Member # 86742 Location: Lincoln, CA 95648 Posts: 127	I agree Novak has great customer service. I ordered a couple of clocking rings from them and when I had questions they were eager to help. I will email them too. Thanks

07-22-2007, 01:26 PM	#8 (permalink)
tinyj9 Registered User Join Date: May 2005 Member # 47085 Posts: 178	I have te same problem with mine but mine is not flipped

07-23-2007, 03:17 PM	#9 (permalink)
crandall Registered User Join Date: Feb 2007 Member # 86742 Location: Lincoln, CA 95648 Posts: 127	I emailed D.E.O. and Novak. Hopefully I will get good news soon. Someone else told JB sells stronger detent spring kits, anyone tried them?

07-25-2007, 06:53 PM	#12 (permalink)
crandall Registered User Join Date: Feb 2007 Member # 86742 Location: Lincoln, CA 95648 Posts: 127	I wanted to post the email response from Down East Offroad Inc. Hopefully this information can help the others in the field with the same problem: Chris, I am familar with your complaint. What we have found is no matter whether the 300 is flipped or not, it is the twin sticks that cause this condition to surface. The springs work in tandam with a single stick design. Twin stick they are forced to handle there on pressure. The problem comes from the slide collars inside the case. When they get some wear on them, they have a tendacy to walk themselves down the shaft and work the shifter into neutral. Some people have fixed them by putting an even stronger spring to hold them in, but the true problem is the shift collars that the shift forks sit in. An Atlas with lots of use on it can do the same thing. Also make sure that the detent balls are fully sitting down inside the shift rail. I hope this helps, Let me know if i can help you anymore. Thanks Robert Bass Down East Offroad Inc.

07-25-2007, 07:26 PM	#13 (permalink)
ld50 Registered User Join Date: Jun 2007 Member # 93767 Location: College Station, TX Posts: 97	look for stronger detent spring it should take care of that, altough a pita to install

07-26-2007, 11:42 AM	#14 (permalink)
tinyj9 Registered User Join Date: May 2005 Member # 47085 Posts: 178	where can you get the stronger springs and detents

07-26-2007, 01:49 PM	#16 (permalink)
ld50 Registered User Join Date: Jun 2007 Member # 93767 Location: College Station, TX Posts: 97	try JBConversions

07-30-2007, 07:33 AM	#20 (permalink)
ld50 Registered User Join Date: Jun 2007 Member # 93767 Location: College Station, TX Posts: 97	From what I remember, putting the stock springs back in was not too easy, cant imagine those things compressing enough to allow room for two bearings in there... I think I would try taking a little of the slope off of the shift rod with a small grinder. just an idea

07-30-2007, 09:30 AM	#21 (permalink)
gr8whytyj Registered User Join Date: Aug 2005 Member # 52005 Location: B-more Posts: 705	When I first flipped mine I had springs in the shifters that were way too stiff made it tough to shift. I had 2 springs, 1 smaller one inside the slightly larger one. I pulled the smaller one out and the case shifted much better, but then the popping out of gear problem came about. I think I will try the bungy cord and coat hanger for a while until I need to drop the trans or case for any other reason. Thanks, Jake.