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Old 10-20-2005, 10:45 PM   #1 (permalink)
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Cracked Dana 300 Case Repair

I picked up a Jeep D300 with good internals but a hairline crack in the case today for $20. Has anyone ever tried to repair a cracked cast iron case? I searched but could only find people repairing the cast aluminum 231s and 241s. It needs to be a sound repair since it will be going behind a 231 crawl box.

I was hoping that I could gut the case, bevel out the crack, preheat, weld with nickel 55 rod (or would nickel 99 be a better choice?), and wrap in insulation to cool.

My hope was that the preheat and slow cool would prevent any heat distortion. It seems to be an easy enough repair but I was wondering if there was something crucial I am overlooking

Thanks for the help, if this needs to be moved to Newbie let me know and I will delete it asap
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Old 10-20-2005, 11:31 PM   #2 (permalink)
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try the nickel rod, PRE AND POST heat. Gas grills work good.
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Old 10-20-2005, 11:58 PM   #3 (permalink)
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A barbeque, great idea. So you would post heat and then wrap it up in insulation to cool slowly?
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Old 10-21-2005, 12:31 AM   #4 (permalink)
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sorry, it would be a doubler. I am planning on mating the planetary gear set of the 231 to the 300, it will function like a doubler whereas you have 2 low ranges too choose from. I haven't decided whether I will go with the mad rooster kit or try to fab up something on my own too make it as short as possible. Its just like a 203/205 doubler only different tcases
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Old 10-21-2005, 04:10 AM   #5 (permalink)
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Why don't you buy a new housing./ That way you won't have to worry about it breaking again after you weld it. I have a coupke that I am not using. Pm me if interested
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Old 10-21-2005, 09:08 AM   #6 (permalink)
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I would love to find a new case but being in Montana, I have only ever found 1 cj in a junkyard and it was a 72, hence no d300. I will pm you about the case
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