dana 300 ran out of oil

[cass]

well last week i drove my jeep to work. 15 miles from home it started screaming like crazy. i thought it was the tranny and drove it on home that night. i took it out last night and put it in 4 low and it was quiet as can be. so i pulled the drain plug on the Transfer Case to have 5 whole drops of oil come out. one of my shift rod thimbles is gone. i power washed the whole underside of the jeep befor i even crawled under it
i should have waited to see if there was oil splattered everywhere. i would guess there was because i park this thing in my shop every night and its never left a puddle under it. in the 15000 miles i have put on this jeep i have never lost a drop out of the Transfer Case . i just checked it last oil change (1500 miles ago)

so anyway i guess my big question is about rebuilding this guy. im very capable with the wrenches but have never done a Transfer Case or tranny. i did rebuild the motor in the jeep by myself. what do i expect doing this? is there any issues with shimming of gears? or is everything just bolt together and no adjustment? im also thinking about putting in a crawl ratio kit. is this worth it? i do off road my jeep a fair amout and think sometimes lower gears would be nice.

any suggestions on where to buy the parts?

 

[Old Dog]

I'd try these guys frist, they have 1st rate products Novak Jeep Conversions - Home

 

[DHugg]

im very capable with the wrenches but have never done a Transfer Case or tranny.

Cass, I found the removal of bearing races (full Novak rebuild kit for Dana 300 ) more than I could handle in my garage. I got the Transfer Case disassembled (except for races and one bearing), cleaned and painted by myself, but went to a local and very good shop for reassembly.

Stuff I read says you can handle the job yourself, but I didn't want to risk a botched job.

One caution: The tcase is very heavy, and after having it topple onto one shoulder during removal, I gained a great respect for gravity and heavy metal masses. The bruises were as colorful as fall foliage for two weeks.

 

[cass]

i am deffinatly going with the novak kit. i think i will just leave the ratio alone. for the cost of that kit i could buy the adapter and put in the sm465 i have stashed in the shed. then i would have granny low gear.

as for the weight of the case, i use a motorcycle jack to take stuff like that out. i used it to take the tranny and transfer out bolted together when i put a new tranny in. i learned my lesson when i was 16 and took the tranny out of my 63 ford falcon with no jack. "heck it cant be that heavy i will just slide it out and set it down" yep it landed on my chest.

 

[tarry99]

well last week i drove my jeep to work. 15 miles from home it started screaming like crazy. i thought it was the tranny and drove it on home that night. i took it out last night and put it in 4 low and it was quiet as can be. so i pulled the drain plug on the Transfer Case to have 5 whole drops of oil come out. one of my shift rod thimbles is gone. i power washed the whole underside of the jeep befor i even crawled under it
i should have waited to see if there was oil splattered everywhere. i would guess there was because i park this thing in my shop every night and its never left a puddle under it. in the 15000 miles i have put on this jeep i have never lost a drop out of the Transfer Case . i just checked it last oil change (1500 miles ago)

so anyway i guess my big question is about rebuilding this guy. im very capable with the wrenches but have never done a Transfer Case or tranny. i did rebuild the motor in the jeep by myself. what do i expect doing this? is there any issues with shimming of gears? or is everything just bolt together and no adjustment? im also thinking about putting in a crawl ratio kit. is this worth it? i do off road my jeep a fair amout and think sometimes lower gears would be nice.

any suggestions on where to buy the parts?

Novak is a good place..........Impact gun, snap ring pliers, bearing and seal drivers, brass drift,long punch, perhaps a press or puller on some bearings or gears that are stuck, dial indicator to measure endplay. Some come apart nicely some require other means............solvent tank or abilty to clean everything.

 

[cass]

well i got the Transfer Case taken apart only to find bad news the out put shaft is ruined. where it has the oil slinger on it and that big gear rides is melted. they want 195 bucks for a new one. so now this Dana 300 is spare parts! im going to the city saturday to pick up a T-176 mated to a Dana 300 for $300! that 176 should be a bit more suited for my 350 chevy!