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Old 10-19-2008, 09:42 AM   #1
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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

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Old 10-19-2008, 09:56 AM   #2
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have you flipped the 300 yet? are you runnin 4:1 gears? i love that t case, i'm runnin one to. good luck.

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Old 10-19-2008, 10:01 AM   #3
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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
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Old 10-19-2008, 11:28 AM   #4
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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.
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Old 10-19-2008, 02:41 PM   #5
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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
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Old 10-19-2008, 03:28 PM   #6
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I've been wanting to do this
but I was thinking of doing the 4.1 and instaling everthing into a stak case
STaK
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Old 10-19-2008, 03:45 PM   #7
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i also thought about the stak replace a case but for 700 dollars i just coulnt make it worth it for me.
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Old 10-21-2008, 03:57 PM   #8
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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
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Old 10-21-2008, 04:10 PM   #9
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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.
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Old 10-21-2008, 04:22 PM   #10
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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.
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Old 10-21-2008, 04:39 PM   #11
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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
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Old 10-21-2008, 07:14 PM   #12
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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.

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Old 10-21-2008, 07:32 PM   #13
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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
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Old 10-21-2008, 09:59 PM   #14
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nice thread, pictures are great
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Old 10-22-2008, 07:13 AM   #15
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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
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Old 10-22-2008, 07:42 AM   #16
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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.
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Old 10-22-2008, 03:14 PM   #17
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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
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Old 10-22-2008, 07:34 PM   #18
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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.
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Old 10-26-2008, 12:53 AM   #19
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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.









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Old 10-26-2008, 12:56 AM   #20
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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

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Old 10-26-2008, 01:10 AM   #21
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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!
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Old 10-26-2008, 01:19 AM   #22
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i lost the other 5/16 nut i had. the wing nut is just a temp for trial fitting till tomorrow.
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Old 10-26-2008, 03:57 PM   #23
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Lol, figured it was something like that. But again, lookin good. Cant wait to see it all finished up!
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Old 10-27-2008, 08:31 PM   #24
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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
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Old 10-28-2008, 03:42 PM   #25
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i hope to get the mount done tonight and then work on the skid
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Old 10-30-2008, 12:11 PM   #26
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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?
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Old 10-30-2008, 12:16 PM   #27
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what is the bolt pattern on the 435? i think it would be a better case for what your doing.
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Old 10-30-2008, 03:46 PM   #28
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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?
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Old 10-30-2008, 03:55 PM   #29
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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
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Old 10-30-2008, 04:11 PM   #30
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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.

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