Dana 300 Rebuild

[Ultrunner]

I have searched the forum and couldn't find anything on this, but I am assembling my Dana 300 after a complete break-down, clean and replacement and noticed the clutch sleeves have different thickness on the ridges on either side of the channel where the shifter forks rest.

I imagine this is a front/rear orientation, but in my haste to get the thing apart I didn't document properly how they were oriented. Does anyone have experience with this and can tell me which side (Fat ridge vs Skinny Ridge) faces with direction on each of the shafts? Thanks in advance. Once complete I'll post a pull rebuild thread with pics.

 

[Lumpy Grits]

Here's one of the best ''how-to's'' on the D/300 I've seen.
http://www.jbconversions.com/pdf/2308.pdf
Hope it helps,
LG

 

[Posi]

Thick side towards gear.

 

[Ultrunner]

Here's one of the best ''how-to's'' on the D/300 I've seen.
http://www.jbconversions.com/pdf/2308.pdf
Hope it helps,
LG

Thanks LG, that guide is awesome. I’m a little upset I didn’t find that before I started. Oh well.

As far as “thick edge towards the gear” I’m not sure what that means b/c there is a gear on either side of the clutch slider. I’m pretty sure I can go with the photos in this guide though. Cheers!

 

[Posi]

Think side to the larger gear.

 

[Ultrunner]

I have completed my Dana 300 rebuild, thanks to everyone on this forum for the advice, the Transfer Case looks awesome and it was hugely satisfying to do the work. Photos coming...

Last thing is to install the drain plug. Does anyone have a particular sealant for this? I was intending to just swab a little Super 300 and call it good.

Also, there is about a pint or so of fluid in it, I will not be re-installing it for quite some time while I finishing my frame-off rebuild; would it make sense to fill it anyway to preserve everything or will the fluid in it be fine until i install the drive train back onto the frame? Thanks.

 

[Lumpy Grits]

I wrap the drain plugs with Teflon tape.
LG

 

[Ultrunner]

I wrap the drain plugs with Teflon tape.
LG

I was thinking of that, too, it would be easier and less of a mess. I hate using Super 300 on small parts, it gets everywhere.