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Old 11-16-2008, 04:53 PM   #1
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np435 np231/dana 300 doubler

Well as some of you know i have been trying to get going on my NP-435 swap since i blew my second ax-15. some back ground information first, i have a 1999 TJ. with a 4.0. the what you need is listed in this post. np435 swap
i gotta give credit to GRN TJ he has been a pretty valuable source of info seeing as we are both trying to achieve the same goal.
first off i would like to add some goals to an already time consuming process. first i didnt like my twin sticks i had and 90% done modifying them. second i see no reason why i shouldn't be able to flat belly my jeep so i ordered two sets of poly bushings for a track bar that i will use to turn into a trans support and t-case support thus flatbellying my jeep (pics to come)
third which should have been expected i figured since i have it out why not rebuild the NP-435. so as i speak its already apart the case is cleaned and painted beautiful rattle can black. i have started inspecting the gears and cleaning them off with some brake clean.
i ordered all the parts needed and had my bell-housing sent to novak conversions to be modified for my crank position sensor. i have pictures but no way to put them up till tonight so i will have them later so everyone can see where i am at. ill keep you guys posted if i forgot anything or any questions that the link above doesn't answer let me know ill try and help

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Old 11-16-2008, 06:00 PM   #2
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here are the pics the np 435 is at the girlfriends since my garage is a shit hole

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Old 11-16-2008, 06:07 PM   #3
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somethings missing
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Old 11-16-2008, 06:11 PM   #4
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flywheel cover-plate and pressure plate get reused tj clutch goes bye bye anyone want a center-force clutch disc? let me know
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Old 11-16-2008, 06:14 PM   #5
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found the thing that was missing and some picks of the doubler its apart right now i went through and took apart the 231 and make sure everything was good and cleaned it out
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Old 11-16-2008, 06:18 PM   #6
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twin sticks and i thought i would put one of my helper demonstrating also one more pic of the 231 where it had to be welded lol its shitty i got the kids at my local tech school to weld it for me for freefifty
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Old 11-17-2008, 09:50 AM   #7
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Yay for hot girlfriends and np435 swaps

I can relate to both!
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Old 11-17-2008, 09:52 AM   #8
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On a more business note, Im glad you got some pics up. Like I said, Im gonna be goin slower than most people wanna pay attention to so I'll watch you get it done and maybe use it to help me through mine. Lookin good man. If you run into anything or you wanna bounce some ideas around let me know.
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Old 11-17-2008, 11:12 AM   #9
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i am tossing around the idea of making my own shifter using gear jammers idea its pretty sick i am gonna call ine the gear rammer lol heres a pic
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Old 11-17-2008, 07:02 PM   #10
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more pics the np 435 all gutted and painted and my garage i cleaned it so i figured i would snap a shot... don't i have a lot of room to work with?
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Old 11-17-2008, 08:06 PM   #11
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is that a mad rooster 231 doubler?
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Old 11-17-2008, 08:18 PM   #12
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no its duffy at 4x4 machine he sells them at pirate 4x4. its $500 not too bad, but i would give duffy time he's one guy running a machine shop making these things lol so he takes a while took me two months to get mine
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Old 11-18-2008, 06:36 AM   #13
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i know how duffy at D@D is
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Old 11-18-2008, 06:38 PM   #14
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I like the doubler, looks good. They are really sweet but for my application I dont think its necessary. So it looks like the inside of that trans is pretty simple eh? I was worried it might be complicated and Id forget how stuff went back together but it doesnt lok bad at all.
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Old 11-18-2008, 09:38 PM   #15
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i will take pics when i rebuild it but basically its four bolts and a snap ring holding all the top gears in lol. you have to change the top shaft (don't know the proper term just know its not called the main shaft, thats the big gears below.) when you get novak adapter to adapt your 231 now that i took it all apart its really easy and makes sense cause the guys at novak told me i would have to basically take the trans completely apart which made me nervous but its no biggy all you need a socket set, snap ring pliers, a hammer and flat head screw driver (the last two are for prying off covers)
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Old 11-19-2008, 11:20 AM   #16
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Im gonna sell my 231 and just flip a D300 and run that instead. After I put the 4:1 in the 300 I will have all the gear I need combined with the trans. But deff. get some pics when you throw it back together.
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Old 11-19-2008, 05:00 PM   #17
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yea well if you want a kit that has everything you need i would look at Down East Offroad: Transfer Cases

they have a pretty killer setup and this guy Flipped Dana 300 Transfer Case

did a complete write up on his install start to finish with some detailed info and some cool ideas it will definatly help you along. i might actually be flipping my t-case back to passenger drop cause i talked to a local mechanic who has a set of dana 60 dodge axles he might hook me up with. the rear is a full floater not sure about the specs of the front like what it has and what not said its either 3.73 or 4.10 which ill take and the rear has a positrack which i don't know how good they are
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Old 11-20-2008, 01:06 PM   #18
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Its probably a Power Lok, I had one of those in a D60 I had around here before I sold it. They are pretty good and if you flip the clutch pacs you can basically turn it into a locker because it'll engage much easier. Thats a good idea though, Im of the mind set that you can never over build but you can certainly underbuild. 4.10's would be perfect I think and when I swap my axles out way down the road Im probably gonna run 4.10's myself.

I dont think I can pay upwards of $500 to flip a 300 though. I read somewhere on how to do it for like $30 on pirate I think. Im gonna find that thread and go from there because A. Im poor and B. I want to see how cheaply a swap like this can be done and make a write up to show everyone you dont have to pay out the ass to do cool stuff like this. Not that there is anything wrong with spending the money if you can afford to do it that way but I just cant. I know theres a few other poor Jeepers out there like myself so Im gonna try to give them some hope, lol.
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Old 11-21-2008, 03:22 PM   #19
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grntj why dont you flip your 300 like i did look at my thread and see how i did it. its in the builders corner.that kit from down east is a friggin money grab you dont have to have shift rails on top.there are a lot of ways of doing it for cheap
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Old 11-21-2008, 10:27 PM   #20
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Yea for sure. Lol, I have such a crappy memory I already forgot you had that thread. Its like if a thread isnt at the top then I forget it was thereI like the way you did it now that I remember and I will likely go the exact same route.
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Old 11-21-2008, 10:52 PM   #21
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its ok i wish more people knew about the builders corner i see people are starting to talk more about big swaps and the are puting them in the other areas and are getting lost in all the other threads that dont relate to them. i was trying to put that nicely but i think you know what i mean
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Old 11-24-2008, 04:54 PM   #22
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Updates bardenk, we need updates!! lol
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Old 11-24-2008, 11:40 PM   #23
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lol sorry i just got the novak conversion today. i gotta take pics and start the rebuild. i run my own company and am busy the next two days but ill take pics of all my new parts
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Old 11-25-2008, 11:39 AM   #24
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Hire me and then you can work on your Jeep!
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Old 11-27-2008, 11:11 AM   #25
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picture time novak adapter and showing what comes with jeff's bronco graveyard rebuild all those needle bearings in the last pic get replaced with the first pic in the next set didnt take pictures of how i got it out but it was interesting torch 3 jaw puller and a deep socket lol
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Old 11-27-2008, 11:16 AM   #26
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the new needle bearings that don't have to be installed individually adapter mocked up and installing gears and little snap ring
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Old 11-27-2008, 11:20 AM   #27
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more gear install pics on new novak shaft helper thought her hands were really dirty lol main-shaft installed she actually helps lol shes bolting up the check cover and the drain and fill plugs.
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Old 11-27-2008, 11:25 AM   #28
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shift cover is a fucking bitch to line up lol still isn't right as we speak but it was 11:30 on tuesday and i had work and school on wed and just gave up. just wanted to know if anyone has any idea how to line that thing up its a huge PITA. thats all for now waiting on the bell-housing
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Old 11-28-2008, 11:24 PM   #29
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Good updates man, that adapter looks pretty nice. Sorry, do real ideas on how to line that up. Hopefully I will get my trans soon so I can be doing it to and try to help ya out. I found one for $80 from a very well running truck so I will probably have it soon.
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Old 12-01-2008, 06:06 PM   #30
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i figured out what the issue was. one of the synchro's was stuck inside the big gear on the main-shaft. so i tapped them apart and greased the main-shaft where the gear slides and the synchro. it works much better now you just have to make sure you have the gears in neutral and the little plastic booty's line up in their appropiate places. i talked to novak today i have to take the adapter off and back the bolts i put into the transmission housing because they are not supposed to stick out at all and they stick out about 1/4 to an 1/8 of an inch all four of them which is kinda crappy. they also tried to ship out my bell-housing so at least i know it will be on its way in a day or two. also i am fighting the pilot bushing cause obviously mine has to be frozen in there. i tried the grease and bolt technique but the bolt i think is still to small. i had a 3/4 and am going to try and find a 7/8 or 15/16 bolt. it is messy as hell by the way. i also read i can try and thread the inside of the of the pilot bushing after i remove the little bearings and thread the bolt until it hits the crank and have it act like a puller ill keep you guys posted on which method works.

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