Dana 300 Rebuild

[Jtoms]

Hey guys,
Another Dana 300 question. Almost have it torn down. Have the Novak rebuild kit, twin stick kit, and Teralow 4:1 kit ready to go. I removed the shift rails and forks last night. Question I have is related to the poppet balls and springs. Everything I've read said they would shoot out. Well they didn't, just one ball fell out and the springs stayed in. But as you can see in the pictures, it looks like there are 2 additional balls still in the output bearing retainer. Should there be 3 poppet balls? Or am I looking at something different. And i guess I just need to work the springs out?

Any help would be appreciated. Also, I'm planning to install the twin stick shifter. I can't find a write up on how to make it truly front and rear independent.

Thanks for the help.

 

[hole]

Except for using LoMax, I'm hopefully doing the same thing to mine this weekend. What I do know is one of the balls is a detent attached to the switch for the 4wd light on the dash. I'll be watching for a better answer though

 

[Lumpy Grits]

Call Novak!
LG

 

[Posi]

Don't try to remove the springs and poppet balls through the holes shown in your pic. There is a plug and switch on top of the housing you have to remove to easily remove the ball and spring.
There are only 2 poppet balls

 

[Jtoms]

Thanks for the reply. How do you remove the plug? And do you need to replace it with a new plug? Or can you use the original?

Thanks again for the reply.

 

[hole]

On mine the plug just un-screwed

 

[Jtoms]

Guys. I appreciate all the help. But I've done a lot of searching and I'm lost. Attached is what I'm working with. How do you remove this plug? Does it need to be drilled out? I should be able to get the 4wd indicator out, but the other one doesn't have a head to it.
Any help would be appreciated.

 

[hole]

Interesting because mine had a plug that screwed in.On a freeze plug that small I would punch a hole with a flat screwdriver and try twisting and then prying it out. Personally I'd avoid drilling because of the shavings. Does your rebuild kit include a new plug?

 

[GARGOYLEJEEPER]

Not a freeze plug but just a plug similar to plug on carb idle screw, pound in with sharp hard object and pry out or pull out with pinch nose . Pound flat again or get new at APS, cheap part tat can become expensive if not sealed back up. If you had one that screwed in it was for a sender to dash indicator, one for in & out other for high & low.

GARGOYLEJEEPER

 

[Jtoms]

Thanks guys. Unscrewed the 4wd indicator and spring came out no problem. The other spring I worked out with a screw driver, but there is no way I'll be able to get the new spring in without getting this plug out. The kit came with 2 plugs, but they only fit in the hole that the indicator was in. I don't even know if the other one is threaded.
So I guess I'll try punching it out and find something that will fit back in there.
Thank you all for the help.