Dana 300 assembly

[Questadg]

I am replacing seals and gaskets on a Dana 300 . I am wondering if anyone has any suggestions for keeping the needle bearings in place on the intermediate gear/shaft. I am thinking of finding a 1-1/4 inch od pipe or something and cut it short enough to fit in the gear cluster and then insert the shaft, pushing the pipe out. I saw reference to a tool but no info where I can get one.

 

[CJ]

Check out this thread (I put some pics in starting at post #20), it's a Dana 20 but the concept is the same.

-->> http://www.jeep-cj.com/forums/f2/t-150-trans-dana-20-t-case-rebuild-1525/#post12069

 

[Saddle Tramp]

You can also use Vaseline to help hold needle bearings in place.. Don’t use regular lube grease as it won’t dissolve when the oil hits it which could cause bearing failure.

 

[jasonmark1993]

Do you need to pull the shaft to do the seals?

I'm trying to remember back to when I did my 20 and it seems like the shaft should be able to stay in there.

 

[tarry99]

I am replacing seals and gaskets on a Dana 300 . I am wondering if anyone has any suggestions for keeping the needle bearings in place on the intermediate gear/shaft. I am thinking of finding a 1-1/4 inch od pipe or something and cut it short enough to fit in the gear cluster and then insert the shaft, pushing the pipe out. I saw reference to a tool but no info where I can get one.

If the finished shaft size OD is 1.25" then use a dummy shaft OD @ 1.188"Cut the shaft just so it long enough to go inside the gear set. Could be a piece of aluminum or plastic rod. Take a good assembly lube made for that purpose and stick it in the freezer for an hour before you use it...........makes it nice and firm and will hold the bearings. Don't forget the thrust washers.

 

[jasonmark1993]

I used frozen vaseline but I still dont see why that shaft has to come out just to do seals.

 

[tarry99]

I used frozen vaseline but I still dont see why that shaft has to come out just to do seals.

Yep, I was thinking the same thing, must be some other repairs, bearings or?

 

[DHugg]

Yep, I was thinking the same thing, must be some other repairs, bearings or?

The intermediate shaft on my Dana 300 offa 1980 CJ7 has a rubber O-ring that is pretty flat, could leak.

Novak's rebuild kit has O-ring replacement parts; I can take a hint.

 

[jasonmark1993]

Ah ok.

The 20s didn't have an O ring. Just a press fit.

Figured the 300 was the same.

Novak's aftermarket intermediate shafts have o rings along with the press fit.

 

[Questadg]

jasonmark1993 is correct. I don't think the intermediate shaft needs to come out just to replace seals. I tend to be a nosy one and I just have to find out how things work. Not the first time I get in a bind, or the last. That's how I learn sometimes. Thanks for all the suggestions. I found a PVC slip joint that is 1-1/4 inches and cut it to fit. Now I cannot seem to get the shifter rods in the shifter forks! Any suggestions? I touched up the rods with emery cloth but the forks will not enter. Guess that's what I get for being so nosy!!

 

[jasonmark1993]

Are you having trouble getting the shift rods back into the case?

There is a detent ball and spring you have to push down on.

Other than that you have the set screw backed out for enough right?

Cant think of anything else.