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So, it's been a few days, and I have probably put around 300 miles on this Scrambler since the Dana 300 intermediate shaft swap. So far so good as far as any leaks, but being a Jeep and a Dana 300, I'm sure it is just a matter of time 😆
I just did this last year on the 4.0 in my red Scrambler. Only advise, really loosen up the other main bearing caps, like a few turns each. I did that, mine came out relatively easy.
Quick test drive late this afternoon, everything seems good to go.
I refilled the transfercase Sunday, Scrambler sat in the same place until Tuesday afternoon, no puddle.
About 2 hours after test drive, no drips, yet.
Will keep an eye on this 🤞
That's it for now.
I had to install the clocking ring as a spacer for the 300 to slide onto the AX15. Then realized, yes, I could get rid of that rear "hump" in the OEM skid, gain some belly clearance, still haven't done it 😅
I figure a few more big rock hits on the rear of that "hump" and I'll have a redneckray...
My home made gasket installed, seems to fit well. Being cork, I like it more then the typical thin paper gaskets used here.
I used the Aviation Sealant on both sides of my cork gasket, thin coats. I used the hardening sealant on the one cover through hole, and on the drain plug threads...
Put the rear driveshaft back in, interior back together, didn't feel like waiting until tomorrow for a gasket to arrive, so bought a sheet of Felpro cork gasket material and made my own Dana 300 inspection cover gasket.
Traced the cover, used a 5/16 hollow punch that fit through the covers...
After the above fiasco, transfer case reinstallation went fairly easy. Transmission jack and six studs coming out of the clocking ring really helped out. Much easier compared to reinstalling a manual transmission.
Cleaned some parts, went ahead and greased the rear driveshaft CV assembly...
Two sets of 24!!!!
About pooped my pants when I found a needle bearing on the work bench, then really hit the ceiling when I flipped the transfer case right side up and another one fell out the bottom!!!
Actually tapped the intermediate shaft back out some to take a peek inside to make sure...
Using the new shaft to hold the rear thrust washer in place.
The front, due to clocking ring, more PIA. Can't get a straight shot, did the best I could. I needed both hands for the intermediate gear.
And just like that it fell right in. Hahahahahahahahah!!!!!!
Minor PIA. My case notch...
Back at it.
Old parts, no abnormal wear or damage.
New parts from Novak that came with their shaft. No idea what the top 3 clips are for, did get two spare O-rings for the intermediate shaft (shaft came with o-rings already installed).
Old needle bearings, two rows of 23. Made sure none...
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