install thread of a dana 300 into my 97 tj

64panhead · 10-19-2008, 10:42 AM

im installing a dana 300 into my 97 tj sport. i decided to do this because it will be better and cheaper in the long run compared to dumping a load of money into the 231 that is living under my jeep right now. i know peaple are going to write up things defending the 231 and as of now i havent had any complaints about it i would rather just do the swap now and not worry about it. so here are some pics

this is the victim

this is the dana 300

this is where its going

**jpdocdave** · 10-19-2008, 10:56 AM

have you flipped the 300 yet? are you runnin 4:1 gears? i love that t case, i'm runnin one to. good luck.

64panhead · 10-19-2008, 11:01 AM

im building a flip shifter for it once its in there ive seen a few toyotas with flip shifters and they work great. no 4.0 kit yet im gonna do 32 spine outputs before the 4.0. right now i just want to get it in there

GrnTJ · 10-19-2008, 12:28 PM

I was wrestling witht the idea of getting a Dana 300 and putting the 4:1 in it. I decided when the time comes Im just going to run a 4.3:1 atlas II instead. Its brand new and its ready to go instead of flipping and rebuilding a 300. I like what your doing though and Im deff. interested to watch this. Good luck, hope it goes smoothly.

64panhead · 10-19-2008, 03:41 PM

well the 231 is out im in the middle of making a template for the bolt pattern and hopefully will have it at least in there tonight

side by side not much difference

here is the big difference over all LENGTH!!!

big hole in there

mr4x4 · 10-19-2008, 04:28 PM

I've been wanting to do this
but I was thinking of doing the 4.1 and instaling everthing into a stak case
STaK

64panhead · 10-19-2008, 04:45 PM

i also thought about the stak replace a case but for 700 dollars i just coulnt make it worth it for me.

64panhead · 10-21-2008, 04:57 PM

here is a bunch of pics. there were 2 holes that had to be elongated a bit. here is a pic of it in there

a front drive shaft from an auto cj7 fits perfectly, here it is sitting in there

right now im working on the shift linkage this is before i did anything to it

also i forgot to mention that the factory trans mount hits the shifter mount so here is a pic of i clearenced

well this is where im at so far, if anyone has any questions or ideas of what i might be doing wrong let me know

flattietj · 10-21-2008, 05:10 PM

did you have to buy an adapter ring........we just put one in a cherokee and had to buy an adapter.......i also have considered this swap......and again buy the time you 4 to 1 it and upgrade the outputs you almost have an atlas so ill break my 231 a few more times.....the cool thing about your swap is you can do alittle at a time unlike the atlas where youve gotta drop 2100 in one shot.

**jpdocdave** · 10-21-2008, 05:22 PM

i picked up my d300 for around $100, 4:1 is around $600, i don't think upgrading the outputs is all that important, its a strong case, way stronger than 231. i will find out the hard way though, so for $700 + a twin stick thats way better than atlas to me, plus you built it, not bought it.

64panhead · 10-21-2008, 05:39 PM

i would loved to been able to have an atlas in there but that kind of money just dosnt exist at least all in one shot for me. the bolt pattern has six bolt and two of them had to be elongated 1/4in down on the trans to get the dana 300 to bolt up. i used a die grinder to cut the holes.

here is a drawing to show what i was talking about

MR.CLIFFORD · 10-21-2008, 08:14 PM

Are you going to clean up your case? It is worth it to spend the extra for the install kit if you are going to do the 32 spline upgrades. I stripped my 300 completely down.

64panhead · 10-21-2008, 08:32 PM

im going to rebuild it and im gonna clean it up, im just leaving it like it is to make shure it will all work. i dont want to put any money into a rebuild or other upgrades until i try it. it is a little greezy for what im going to do with it over the corse of the winter this is just the first step

jeepocalypse · 10-21-2008, 10:59 PM

nice thread, pictures are great

flattietj · 10-22-2008, 08:13 AM

it think that the output shaft upgrades are a must if you are 4:1ing the tcase.......we have two in our group with the 4:1s and no shaft upgrades that are sitting broke b/c of a front output break........this all happened in the last year

GrnTJ · 10-22-2008, 08:42 AM

Lol, are either of those due to the driving at Harlan Jake? I havent seen you guys wheel anywhere else but I could see it having happened there, especially the way jason drove.

flattietj · 10-22-2008, 04:14 PM

most of it on fairly easy stuff in ohio......if you are leaving a 300 with the standard reduction then the outputs are fine.......by 4:1in it you are putting almost double the torque on the outputs and they are not built for that......although anything can hold together depending on driving style.....my style is a point and shoot so the standard outputs would break. i am not trying to p in anyones cheerios and you will be able to upgrade in the future if needed......"the reason i like this swap"......u dont have to spend it all at once to get a better from the get go tcase

64panhead · 10-22-2008, 08:34 PM

thats what im talking about, from a stock case 231 going to stock case 300 its the best case to swap to for the least amount of money.plus i can upgrade it as i go in the order i want.

64panhead · 10-26-2008, 01:53 AM

i spent most of the night working on the shifters. i had to shorten the shift rails about a half inch then redrilled them to fit the pinsi used 5/16 bolts and ground flat spots on each side to fit them in the slots in the rails. i sandwiched 2 pieces of 1/8in flat stock togather and welded them to start making the handles. i had to bend them around the front out put and between the t-case. well anyways here are a bunch of pics.

64panhead · 10-26-2008, 01:56 AM

i had it in there 5 or 6 times test fitting everything a couple of the pics were of the rails or levers hitting the trans. here are some more

GrnTJ · 10-26-2008, 02:10 AM

Thats sweet man, looks like everything is workin out pretty well. Haha, love the wing nut. I honestly dont remember the last time I saw a wing nut used on anything. Thats besides the point. Keep up the good work!

64panhead · 10-26-2008, 02:19 AM

i lost the other 5/16 nut i had. the wing nut is just a temp for trial fitting till tomorrow.

GrnTJ · 10-26-2008, 04:57 PM

Lol, figured it was something like that. But again, lookin good. Cant wait to see it all finished up!

jeepocalypse · 10-27-2008, 09:31 PM

that grinder wasnt even plugged in! it was powered completely with love (unlike tools in my garage powered with the tortured souls of the damned)

stopped by to see that trans mount but no lights were on so i took off. had the new stencil with me you need to check it out. again great thread

64panhead · 10-28-2008, 04:42 PM

i hope to get the mount done tonight and then work on the skid

GrnTJ · 10-30-2008, 01:11 PM

Um, can you give me more pics please

I decided Im gonna put a 300 behind my np435 swap instead and now I am even more interested in your thread. So all you really need to do to flip it is build the flip shifter? Or is there more to it? Im probably gonna build (or atleast try first before I spend the dough on an expensive adapter from advance or novak) by own trans/tcase adapter to try and mate the 300 to the 435.
So, how is it commin anyway, almost done?

64panhead · 10-30-2008, 01:16 PM

what is the bolt pattern on the 435? i think it would be a better case for what your doing.

GrnTJ · 10-30-2008, 04:46 PM

The D300 is actually the best choice for what Im doing. Trust me, I have searched the other options tirelessly. You mean the bolt pattern for the tcase adapter?

64panhead · 10-30-2008, 04:55 PM

ok i didnt know you were going to go with an adaptor i thought you may have just found something in a junk yard that would work i have 27 dollars in this swap right now that includes the pipe for the rear drive shaft which im building my self and i made my own shifters and used a die grinder to match up the bolt pattern between them

GrnTJ · 10-30-2008, 05:11 PM

Thats what Im trying to figure out. I dont wanna have to buy an expensive adapter. Im gonna try to make one to mate the trans and tcase together (since theres no factory adapter to amte a np435 trans and D300 tcase obvisiouly). Im gonna have to buy and output shaft for the trans though I think so it splines into the D300.

10-19-2008, 10:42 AM	#1
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	install thread of a dana 300 into my 97 tj im installing a dana 300 into my 97 tj sport. i decided to do this because it will be better and cheaper in the long run compared to dumping a load of money into the 231 that is living under my jeep right now. i know peaple are going to write up things defending the 231 and as of now i havent had any complaints about it i would rather just do the swap now and not worry about it. so here are some pics this is the victim this is the dana 300 this is where its going __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-19-2008, 10:56 AM	#2
jpdocdave The Doctor is Out WF Supporting Member Join Date: Mar 2008 Location: beach park, il Posts: 7,138	have you flipped the 300 yet? are you runnin 4:1 gears? i love that t case, i'm runnin one to. good luck. __________________ I got probs Project "Crazy Red Head":http://photobucket.com/yj_build_pics as of 9/09

10-19-2008, 11:01 AM	#3
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	im building a flip shifter for it once its in there ive seen a few toyotas with flip shifters and they work great. no 4.0 kit yet im gonna do 32 spine outputs before the 4.0. right now i just want to get it in there __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-19-2008, 12:28 PM	#4
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	I was wrestling witht the idea of getting a Dana 300 and putting the 4:1 in it. I decided when the time comes Im just going to run a 4.3:1 atlas II instead. Its brand new and its ready to go instead of flipping and rebuilding a 300. I like what your doing though and Im deff. interested to watch this. Good luck, hope it goes smoothly. __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-19-2008, 03:41 PM	#5
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	well the 231 is out im in the middle of making a template for the bolt pattern and hopefully will have it at least in there tonight side by side not much difference here is the big difference over all LENGTH!!! big hole in there __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-19-2008, 04:28 PM	#6
mr4x4 Jeeper Join Date: Sep 2006 Location: pahrump Nevada Posts: 1,235	I've been wanting to do this but I was thinking of doing the 4.1 and instaling everthing into a stak case STaK

10-19-2008, 04:45 PM	#7
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i also thought about the stak replace a case but for 700 dollars i just coulnt make it worth it for me. __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-21-2008, 04:57 PM	#8
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	here is a bunch of pics. there were 2 holes that had to be elongated a bit. here is a pic of it in there a front drive shaft from an auto cj7 fits perfectly, here it is sitting in there right now im working on the shift linkage this is before i did anything to it also i forgot to mention that the factory trans mount hits the shifter mount so here is a pic of i clearenced well this is where im at so far, if anyone has any questions or ideas of what i might be doing wrong let me know __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-21-2008, 05:10 PM	#9
flattietj Jeeper Join Date: Aug 2008 Posts: 573	did you have to buy an adapter ring........we just put one in a cherokee and had to buy an adapter.......i also have considered this swap......and again buy the time you 4 to 1 it and upgrade the outputs you almost have an atlas so ill break my 231 a few more times.....the cool thing about your swap is you can do alittle at a time unlike the atlas where youve gotta drop 2100 in one shot.

10-21-2008, 05:22 PM	#10
jpdocdave The Doctor is Out WF Supporting Member Join Date: Mar 2008 Location: beach park, il Posts: 7,138	i picked up my d300 for around $100, 4:1 is around $600, i don't think upgrading the outputs is all that important, its a strong case, way stronger than 231. i will find out the hard way though, so for $700 + a twin stick thats way better than atlas to me, plus you built it, not bought it. __________________ I got probs Project "Crazy Red Head":http://photobucket.com/yj_build_pics as of 9/09

10-21-2008, 05:39 PM	#11
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i would loved to been able to have an atlas in there but that kind of money just dosnt exist at least all in one shot for me. the bolt pattern has six bolt and two of them had to be elongated 1/4in down on the trans to get the dana 300 to bolt up. i used a die grinder to cut the holes. here is a drawing to show what i was talking about __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-21-2008, 08:14 PM	#12
MR.CLIFFORD WINNAR!!!!!! Join Date: Nov 2005 Location: THE PROVING GROUNDS Posts: 4,522	Are you going to clean up your case? It is worth it to spend the extra for the install kit if you are going to do the 32 spline upgrades. I stripped my 300 completely down. __________________ YOU CAN ONLY WIN WHEN I'M NOT AFRAID TO LOSE!

10-21-2008, 08:32 PM	#13
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	im going to rebuild it and im gonna clean it up, im just leaving it like it is to make shure it will all work. i dont want to put any money into a rebuild or other upgrades until i try it. it is a little greezy for what im going to do with it over the corse of the winter this is just the first step __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-21-2008, 10:59 PM	#14
jeepocalypse Jeeper Join Date: Sep 2007 Posts: 52	nice thread, pictures are great

10-22-2008, 08:13 AM	#15
flattietj Jeeper Join Date: Aug 2008 Posts: 573	it think that the output shaft upgrades are a must if you are 4:1ing the tcase.......we have two in our group with the 4:1s and no shaft upgrades that are sitting broke b/c of a front output break........this all happened in the last year

10-22-2008, 08:42 AM	#16
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	Lol, are either of those due to the driving at Harlan Jake? I havent seen you guys wheel anywhere else but I could see it having happened there, especially the way jason drove. __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-22-2008, 04:14 PM	#17
flattietj Jeeper Join Date: Aug 2008 Posts: 573	most of it on fairly easy stuff in ohio......if you are leaving a 300 with the standard reduction then the outputs are fine.......by 4:1in it you are putting almost double the torque on the outputs and they are not built for that......although anything can hold together depending on driving style.....my style is a point and shoot so the standard outputs would break. i am not trying to p in anyones cheerios and you will be able to upgrade in the future if needed......"the reason i like this swap"......u dont have to spend it all at once to get a better from the get go tcase

10-22-2008, 08:34 PM	#18
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	thats what im talking about, from a stock case 231 going to stock case 300 its the best case to swap to for the least amount of money.plus i can upgrade it as i go in the order i want. __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-26-2008, 01:53 AM	#19
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i spent most of the night working on the shifters. i had to shorten the shift rails about a half inch then redrilled them to fit the pinsi used 5/16 bolts and ground flat spots on each side to fit them in the slots in the rails. i sandwiched 2 pieces of 1/8in flat stock togather and welded them to start making the handles. i had to bend them around the front out put and between the t-case. well anyways here are a bunch of pics. __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-26-2008, 01:56 AM	#20
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i had it in there 5 or 6 times test fitting everything a couple of the pics were of the rails or levers hitting the trans. here are some more __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-26-2008, 02:10 AM	#21
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	Thats sweet man, looks like everything is workin out pretty well. Haha, love the wing nut. I honestly dont remember the last time I saw a wing nut used on anything. Thats besides the point. Keep up the good work! __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-26-2008, 02:19 AM	#22
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i lost the other 5/16 nut i had. the wing nut is just a temp for trial fitting till tomorrow. __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-26-2008, 04:57 PM	#23
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	Lol, figured it was something like that. But again, lookin good. Cant wait to see it all finished up! __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-27-2008, 09:31 PM	#24
jeepocalypse Jeeper Join Date: Sep 2007 Posts: 52	that grinder wasnt even plugged in! it was powered completely with love (unlike tools in my garage powered with the tortured souls of the damned) stopped by to see that trans mount but no lights were on so i took off. had the new stencil with me you need to check it out. again great thread

10-28-2008, 04:42 PM	#25
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	i hope to get the mount done tonight and then work on the skid __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-30-2008, 01:11 PM	#26
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	Um, can you give me more pics pleaseI decided Im gonna put a 300 behind my np435 swap instead and now I am even more interested in your thread. So all you really need to do to flip it is build the flip shifter? Or is there more to it? Im probably gonna build (or atleast try first before I spend the dough on an expensive adapter from advance or novak) by own trans/tcase adapter to try and mate the 300 to the 435. So, how is it commin anyway, almost done? __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-30-2008, 01:16 PM	#27
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	what is the bolt pattern on the 435? i think it would be a better case for what your doing. __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-30-2008, 04:46 PM	#28
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	The D300 is actually the best choice for what Im doing. Trust me, I have searched the other options tirelessly. You mean the bolt pattern for the tcase adapter? __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

10-30-2008, 04:55 PM	#29
64panhead Jeeper Join Date: Sep 2007 Location: massena ny Posts: 336	ok i didnt know you were going to go with an adaptor i thought you may have just found something in a junk yard that would work i have 27 dollars in this swap right now that includes the pipe for the rear drive shaft which im building my self and i made my own shifters and used a die grinder to match up the bolt pattern between them __________________ 1997 jeep tj sport 4.0 1986 suzuki lt250r quadracer 1968 triumph t120r bonneville 1998 dodge ram 1500

10-30-2008, 05:11 PM	#30
GrnTJ Jeeper Join Date: Jul 2007 Location: Pinckney, Michigan Posts: 1,485	Thats what Im trying to figure out. I dont wanna have to buy an expensive adapter. Im gonna try to make one to mate the trans and tcase together (since theres no factory adapter to amte a np435 trans and D300 tcase obvisiouly). Im gonna have to buy and output shaft for the trans though I think so it splines into the D300. __________________ Yes I know my TJ is red custom long arms, locked and geared hp44/9", 36" tsl's on double beadlocks, warn 8274, hi steer, some armor, and a few other things... Ford 302, np435, doubled 300/231, and cage comming this summer.

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