$20 Dana 300 flip kit

Tass · 07-22-2003, 04:32 PM

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

Tass · 07-22-2003, 04:33 PM

The next pic is basically the same thing. It's hard to see but it shows how close the two shift forks are.

Tass

Tass · 07-22-2003, 04:35 PM

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)

Tass

Tass · 07-22-2003, 04:41 PM

Next is with the top plate on and the shifters installed. Sorry the pic is blurry.

Tass

rokcrln · 07-22-2003, 04:50 PM

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.

66CJdean · 07-22-2003, 05:00 PM

Looks cool. The shifters for the 300 look like toy shifters???

Tass · 07-22-2003, 05:01 PM

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.

Tass

Tass · 07-22-2003, 05:02 PM

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

Tass

66CJdean · 07-22-2003, 05:13 PM

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?

BJ On Roids · 07-22-2003, 06:28 PM

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)

Damo · 07-22-2003, 07:59 PM

Quote:

Originally posted by BJ On Roids
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.

madmarx · 07-22-2003, 08:06 PM

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.

Tass · 07-22-2003, 08:08 PM

[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.

Tass

Damo · 07-22-2003, 08:13 PM

Quote:

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?

madmarx · 07-22-2003, 10:12 PM

Nope, I never took mine apart so I could take out the interlock pill.. I imagine it would blow up pretty dang fast

TN William · 07-23-2003, 06:18 AM

Can you make me one for $20?

RUFF · 07-23-2003, 06:28 AM

Quote:

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

wilburburns · 07-23-2003, 08:56 AM

Are there any lubrication issues or problems with flipping a D300?

Cliff

Jeepmangled87 · 07-23-2003, 11:20 AM

not a bad setup.

GoodeJ · 07-23-2003, 11:41 AM

Sweet!!! I'll have to remember this option when I go full size!!!

BrettM · 07-23-2003, 12:25 PM

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...

Tass · 07-23-2003, 03:15 PM

Quote:

Originally posted by BrettM
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

Tass

saprobe · 07-23-2003, 08:13 PM

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

GoatASS · 08-11-2003, 12:00 PM

have you taken this on the trail yet? how is it holding up?

ashmanjeepXJ · 08-11-2003, 12:27 PM

COOL

07-22-2003, 04:32 PM	#1
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	$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 Attached Images __________________ Nothing to see here, move along.............

07-22-2003, 04:33 PM	#2
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	The next pic is basically the same thing. It's hard to see but it shows how close the two shift forks are. Tass Attached Images __________________ Nothing to see here, move along.............

07-22-2003, 04:35 PM	#3
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	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) Tass Attached Images __________________ Nothing to see here, move along.............

07-22-2003, 04:41 PM	#4
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	Next is with the top plate on and the shifters installed. Sorry the pic is blurry. Tass Attached Images __________________ Nothing to see here, move along.............

07-22-2003, 04:50 PM	#5
rokcrln Registered User Join Date: Jul 2001 Member # 5821 Location: Lost in my own head! Posts: 1,414	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. __________________ Buildem--Rollem--Tearem Apart--Get Rid of the Wife--And Start All Over! BRONCO BUGGY; dana44,35spln 9", 37's, 351W efi, C5full manual w/comp brk, atlass 5:1, fox 16" air's master craft rubicon's, full hydro, and a girl friend that loves to help.

07-22-2003, 05:00 PM	#6
66CJdean Pirate4x4 Addict! Join Date: May 2000 Member # 940 Location: Lincoln, Ca Posts: 6,201	Looks cool. The shifters for the 300 look like toy shifters??? __________________ WWW.PCRYO.COM Deep Cryogenic Tempering Service Find all my products at www.KICKASSOFFROAD.COM 916-434-6978 Custom Axles built to order. 4340, TorMax, or 300M Custom Hummer wheels and centers Axle Resplining

07-22-2003, 05:01 PM	#7
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	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. Tass __________________ Nothing to see here, move along.............

07-22-2003, 05:13 PM	#9
66CJdean Pirate4x4 Addict! Join Date: May 2000 Member # 940 Location: Lincoln, Ca Posts: 6,201	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? __________________ WWW.PCRYO.COM Deep Cryogenic Tempering Service Find all my products at www.KICKASSOFFROAD.COM 916-434-6978 Custom Axles built to order. 4340, TorMax, or 300M Custom Hummer wheels and centers Axle Resplining

07-22-2003, 06:28 PM	#10
BJ On Roids Registered User Join Date: Aug 2001 Member # 6588 Location: 'Straya....mate Posts: 7,432	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) __________________ [COLOR=yellow]Bj on Roids 1970FJ45, Quad Cam V8, Auto, Broken T-case, H-TEC (traction control and cutting brakes) 42 TSLs.[/COLOR] [COLOR=green][URL=http://www.outerlimits4x4.com]Aussie Wheelers Bulletin Board[/URL] [/COLOR]

07-22-2003, 08:08 PM	#13
Tass Registered User Join Date: Aug 2000 Member # 1516 Location: London Ontario Canada Posts: 568	[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. Tass __________________ Nothing to see here, move along.............

07-22-2003, 10:12 PM	#15
madmarx Registered User Join Date: Jun 2001 Member # 5115 Location: Chattanooga Tn Posts: 723	Nope, I never took mine apart so I could take out the interlock pill.. I imagine it would blow up pretty dang fast

07-23-2003, 06:18 AM	#16
TN William Registered User Join Date: Feb 2002 Member # 10283 Location: Kingston, TN Posts: 98	Can you make me one for $20?

07-23-2003, 08:56 AM	#18
wilburburns Web Designer-Host Join Date: Mar 2003 Member # 18120 Location: Ky Posts: 153	Are there any lubrication issues or problems with flipping a D300? Cliff

07-23-2003, 11:20 AM	#19
Jeepmangled87 ROCK & ROLL OFFROAD Join Date: Mar 2001 Member # 3906 Location: ROCK AND ROLL OFFROAD Dallas/Ft.Worth Tx. Posts: 5,059	not a bad setup. __________________ ROCK AND ROLL OFFROAD 877-765-8774 Dallas/Ft Worth OFFROAD MEGA STORE. www.shoprockandrolloffroad.com www.rockandrolloffroad.com www.forumrockandrolloffroad.com RED YJ-42's 60-14-fox TEAM 7238 BITD BORN TO KILL

07-23-2003, 11:41 AM	#20
GoodeJ Registered User Join Date: Aug 2002 Member # 13056 Location: Rocklin,Ca. Posts: 63	300 Flip Sweet!!! I'll have to remember this option when I go full size!!! __________________ Blue Ribbon, UFWDA, CORVA LIFETIME Member RTP, Friends of "Everything I can" KG6WSR

07-23-2003, 12:25 PM	#21
BrettM Registered User Join Date: May 2002 Member # 11998 Location: Michifornia Posts: 4,035	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... __________________ awshifting.com awshifting@gmail.com

08-11-2003, 12:00 PM	#24
GoatASS Registered User Join Date: Jul 2003 Member # 21338 Location: Auburn, CA Posts: 365	have you taken this on the trail yet? how is it holding up?

08-11-2003, 12:27 PM	#25
ashmanjeepXJ Cherokee Moderator Join Date: Feb 2002 Member # 10249 Location: NW Tucson, Arizona Posts: 3,130	COOL __________________ 88XJuggy, LPG 383-th400-203-205, d60-14B, 42inTSLs 70 FJ40, 350-SM465-205, d44-14B, 38inTSLs, RIP Josh Come wheel with us WheelingArizona.com

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode