My Blue Jeep

[Ron84cj]

Let me know if you need any parts. I think I might have some spare output shaft seals, maybe even some good used bearings. I might even have some good used other parts and pieces.

You could rebuild this one with the stock low ratio, buy another 300 to install the 4:1 gears. Once you install the 4:1 case, sell the stock rebuilt case to recoup some $$$ ??

Thanks, that's a good idea. I'll keep my eye out for another one. I really regret selling my spare Dana 300 now. I really didn't think I would need it. I'm eyeballing the kit from Advance Adapters right now. Anyone have any recommendations?

 

[spankrjs]

Thanks, that's a good idea. I'll keep my eye out for another one. I really regret selling my spare Dana 300 now. I really didn't think I would need it. I'm eyeballing the kit from Advance Adapters right now. Anyone have any recommendations?

I think I have used the Novak kits before, they were pretty good.

I never looked, but I wonder if it would be cheaper to buy the bearings and input/output/shift rail seals from a bearing supply house?

 

[Ron84cj]

I see some kits come with the intermediate shaft and some don't. Do these normally go bad? Is it worth just buying one right away?

 

[spankrjs]

I see some kits come with the intermediate shaft and some don't. Do these normally go bad? Is it worth just buying one right away?

I have been reusing the OEM intermediate shafts, they seem better quality then the replacement parts

The only thing riding on that shaft is the intermediate gear, which runs on all of those individual roller bearings. If your original shaft is bad when you pull it, let me know, I have spare new/replacement shafts.

 

[Ron84cj]

Oh boy, here we go....


I started with my clocking ring. I put a little mark on top so I wouldn't forget how I had it.

Couple little marks on the yokes too so they don't get mixed up. Not sure if this matters but generally I try to keep things the same way they came off.


Oh look.... there's gears and things that spin in there.


The sensor and the little cap thing.


The bolt the holds the tag also holds the intermediate shaft. Let's take that little guy out.
Smack the shaft...

 

[Ron84cj]

And it's out.

There are washers in there along with a few of the needle bearings that fell out. I just grabbed them with a magnet.


Ah, the lovely set screws that gives everyone trouble. Before I even tried the Allen wrench on it I beat the crap out of both of them ahead of time with a punch and hammer to "shock them". They both came loose comfortably. I didn't remove them. Just backed them off.

Now this can come off. A little awkward, but not terrible.

Once that's out of the way the forks can come out.

 

[Ron84cj]

Didn't want to damage the speedo gear so I removed that before I forgot.


Let's take off more random stuff...


There's a collar thing in there. There is writing on one side of it. Not sure if this matters but I'll put it back the same way.

 

[Ron84cj]

Took off the plate and shim. The bearing race just slides out by hand.




Unbolting more things...

I smacked a piece of wood with a hammer to separate the two housings.

Then hit the shaft with my dead blow.

 

[Ron84cj]

So now at this point I need a press to get the bearings off and apart the rest of the way. I'll do that tomorrow.

Let's go back to this little guy...the input shaft. Pop off that little snap ring on top.


And the source of the noise.


This bearing is badly pitted/damaged. You can see it on the balls.


Another snap ring to take off.

 

[Ron84cj]

The bearing didn't quite want to come out. So I took my torch and just gave the aluminum around the bearing just a little heat. Didn't take much and I was able to tap out the bearing.


That's it for tonight. I'll press everything apart tomorrow.

 

[Chamba]

Now that's a satisfying day in my books. Time for a well- earned IPA.

 

[spankrjs]

Looking good

The biggest PIA with rebuilding the Dana 300 is reinstalling the shift rails. It takes a little finesse and patience, you will see what I mean LOL!!!

 

[Belizeit]

2 X on the shift rails

 

[Ron84cj]

What anaerobic sealer did you guys use? When I googled it there is a very wide variety of answers.

 

[spankrjs]

What anaerobic sealer did you guys use? When I googled it there is a very wide variety of answers.

I used this stuff:

https://www.napaonline.com/en/p/PTW7651189

I "think" there is a "primer" you are supposed to use, too:

https://www.napaonline.com/en/p/PTW7651154?cid=paidsearch_shopping_dcoe_google&campaign=GSC-Paint-Body-Equipment&campaign_id=10947560788&adgroup_id=110533803034&adtype=pla_with_promotion&gclid=EAIaIQobChMI8r251u358QIVojY4Ch0xqQgXEAQYASABEgJQefD_BwE&gclsrc=aw.ds&

I used the primer, not sure if it is 100% necessary or not? Probably more important that the mating surfaces be perfectly clean

 

[Belizeit]

I used this stuff:

https://www.napaonline.com/en/p/PTW7651189

I "think" there is a "primer" you are supposed to use, too:

https://www.napaonline.com/en/p/PTW7651154?cid=paidsearch_shopping_dcoe_google&campaign=GSC-Paint-Body-Equipment&campaign_id=10947560788&adgroup_id=110533803034&adtype=pla_with_promotion&gclid=EAIaIQobChMI8r251u358QIVojY4Ch0xqQgXEAQYASABEgJQefD_BwE&gclsrc=aw.ds&

I used the primer, not sure if it is 100% necessary or not? Probably more important that the mating surfaces be perfectly clean

I used the same and got it there also.

 

[Ron84cj]

Thanks guys

 

[Ron84cj]

Alright, since you guys brought up the shift rails I thought I'd tackle them next. I put the assembly in the vise first.


I unbolted the front plate/seal holder thing and turned the one rail 90 degrees.


Then as I slide the rail out I fed in a piece of round stock from the other side to keep the detent ball in place.

This made replacing the seal very easy.

And new one installed.

 

[Ron84cj]

The other rail I tried to do the same thing but no luck. I tried various positions with each rail and couldn't get it out. Pretty annoying, that's 5 minutes of my life I won't get back.

So instead of wasting time on this I hammered in a screwdriver on an angle and just pried it out. I did of course clean/ lightly sand both rails before I did anything with them.


I found a socket big enough to fit over the top so I could install the second seal.


Bolted the plate back on and done with this for now.

Wow, what kind of Santa Claus crap is this!?!? The aftermarket intermediate shaft is on top and the factory one is on the bottom. Notice how the nice the finish is on the factory one and how rough the aftermarket one is? As a toolmaker I am crying right now just thinking about it. How the hell does anyone F up a grinding finish that bad?

 

[Belizeit]

Someone told me to use drum sticks so that is what I used. A few years back CJ7Pilot gave me, not sure what it's called, he made them, little fiber donuts to go over the seals to help keep them clean. I installed them last fall.