Dana 300 Transfer Case Rebuild - Part 1 - Tear Down

[@GearBoxVideo]

When my shop was up north in NY I did a great deal of transfer case work. Now in Florida I don't see much. I took this job in to do a video because some of the other videos on this subject seem to display and overuse of hammers and ignore what components load up other parts making for a difficult tear down. Hopefully some of the techniques and logic I display can be used for your own future projects. Thanks... Paul

[@TractorWrangler01]

Really love your videos. I mean that sincerely. I'll be shooting you an email because I have a mod I did to my press that your going to love.

[@mikeskidmore6754]

Hey Paul @GearBoxVideo I have some FWD 3 speed Transfer cases that need rebuilt .. they only weight #1,050 pounds .. I boult a spinning stand to rebuild them on .. The Gears are so heavy you have to lift them with a cherry picker .. so glad most of the shafts have two small holes drilled and tapped so I can thread some lift hooks into them .. I made notes in my repair manual step by step what to do .. It took me several days to rebuild them they way I wanted it .. All Ball bearing the gears used to be $2,000 Each FWD wanted $25,000.00 just for one ring gear and Pinion I bought the last Counterfeit one left for $1,850.00 I have dozens of spared in 5.285 but my truck uses 6.167 ration .. Even Ball Bearings are super expensive now days .. Some times they look good but are about ready to blow .. I head some Stories of FWD three speed transfer cases blowing up on their maiden voyage from Factory in Clintonville Wi to the Dealer..

[@kevinhornbuckle]

Mike Skidmore Do you have a video of these? I'd love to see your work.

[@MrConstant1]

Rocking video. I'm looking to do a rebuild but with lomax gears. Total upgrade to the box using jb conversions parts. It requires notching the case a bit for the larger gears. I'd love to see that done. The off road community would likely love to see that. Just a suggestion. Great video, love your contribution to the art.

[@GearBoxVideo]

I don't have an unlimited budget to buy parts, a transfer case and set time aside for a free video. Although I understand your enthusiasm and how it can be a benefit for the community maybe send me your transfer case and gears and we can work something out.

[@raychilcote5558]

Getting ready to rebuild my Scout Dana 300 and this video is GOLD! Thank you for taking the time and effort to put this together. Wish you were closer (I'm in NC). My TC has developed a grinding tick in 2wd (hi or low). Put it in front wheel drive only, goes away. Figure it's time to replace the bearings (well, a whole rebuild). Likely it's first rebuild since 1980. Thanks again.

[@JamesMcNamara-j1g]

Thank you for sharing this in such a clear and thoughtful way. So many people try to make it a music video with back story about their neighbors Unkle’s lawn mowers previous owner. I intend to do this job soon, currently living on the road in a 5th wheel with no shop. Gonna be fun! (Insert freebird for back ground) lol

[@SvcGlobal]

Hello Paul, nice to meet you again in a new video. It is a real mechanical lesson every time I see you here. Thank you.

[@GearBoxVideo]

Thanks for watching

[@LeoKahng]

Paul - thank you SO much for making this 2-part series for the Dana 300 rebuild! I am in the middle of a frame-off restoration of a 1981 Jeep CJ7 and your videos are an amazing resource for this procedure on the Dana 300. It has been a great learning resource and has saved me at least hundreds of dollars of labor costs. Thank you very much!

[@GearBoxVideo]

Thanks please consider sharing my videos

[@randytravis3998]

looks like the same as my jeep transfer case .. had a few of the covers off mine too fix oil leaks ,, Glad I found this video and your channel and subscribed ,, you are a great teacher ,, your videos are a top 10 ..

[@SidewaysTA]

Another awesome series Paul. Keep'em coming. Take care!

[@t5montecarlo]

Hey Paul, thanks for letting me join you in your shop today, I enjoyed it.

[@blueduster74]

Thanks for the video. I've run a D300 in my 79 Ramcharger for 17 years. I completely part time swapped it with 80s Dodge hubs, knuckles and etc and added a mild magnum 360/NV4500 as well. I've been mindful of the throttle as best I can although Moab doesn't always allow for that. LOL Swapping to a lightly modded 5.7 hemi Eagle and I'm getting the 32 spline hardened output and maybe a hardened intermediate as well. This will make the process easier. I've never had it apart, had 81k on it when I bought it and have put another 45k on it in the Ramcharger. But I figure it's time to rebuild and upgrade before the hemi swap is finished.

[@ImJeff1965]

Awesome video! I’m told often that I’m stupid to start bolts by hand first. Things rust awfully up here in Maine. I smiled when I saw you do the same thing!

[@g1ng3r117]

I enjoy your videos. Very well placed camera. I like your explanations. Giving me the confidence that I can reseal my cj7 transfer case

[@GearBoxVideo]

You can do it!

[@zerogearedfilms397]

Thanks for taking the time to share

[@hddm3]

Glad to see you again in 2019! Good health and godbless

[@BritishBoy1971]

That was a great tip about heating up the studs, then shocking them. It made the job so easy!! Thanks. 🙂👍

[@immikeurnot]

Heavy is almost an understatement with that little Dana 300, but it's so much stronger than newer chain-driven transfer cases.

[@BustedClassicGarage]

Thanks Paul, very informative as usual. I need to rebuild my transfer case for my Cherokee at some point. Great reference material!

[@Domobomb]

Hey Paul, great video!! Always appreciate when you share your knowledge. I hope to see part 2 of the 4+3 Doug Nash OD rebuild in the future!

[@niner09]

Whoever gave this video a thumbs down is an idiot. Thank you for the video! The sequencing and methods have been extremely beneficial as I rebuild mine.

[@mikejensen-fogt4662]

great video! i just watched it to see what im getting myself in to but im sure ill have to watch it again, step by step, while rebuilding my dana 300 lol... thanks for the great info! :)

[@dieselwagoneer18]

You've got some great videos, thank you for sharing your experience.

[@GearBoxVideo]

Glad you like them!

[@BlindBatG34]

Paul, as always you make it look easy. I prefer to leave anything with individual needle bearings to the pros. My blood pressure goes up just seeing all those things drop everywhere.

[@lewwoodthing]

WOW! Another great video Paul, Thanks

[@shotdog4237]

as always another priceless video

[@evolati12]

Very good, informative video! Thanks for taking the time.

[@1crazynordlander]

Thanks for sharing. I think this is the same transfer case my '84 Jeep CJ7 has in it. I think they were a pretty tough unit.

[@ArmstrongRacing]

Very cool, I’ve definitely never had one of these apart before. Interested in what measurements this requires

[@ZAMsChannel]

Great video, as always. Would have loved to know a bit more about what was wrong with the TC and how this "wrong" felt when having been in use. And also where and how to see "the wrong" at the hardware finally. Looking forward to part 2. :-)

[@GearBoxVideo]

I got the transfer case in just to be gone thru for a restoration. The customer purchased it without any knowledge of previous problems I did find some issues with it that will be discussed in part 2

[@ZAMsChannel]

Thanks, Paul! Looking forward to part 2. Learning a lot from you, although I only work on motorcycles on hobby base.... Also those have transmissions and bearings... :-)

[@wolfganghofer6040]

Very informative video as im tearing my case apart. At 19:10 you show two shims, the case I opened (which has been rebuilt by someone else previously) does not have these shims in it. How would I go about shimming the case properly? Thank you

[@GearBoxVideo]

The info is in the video. Shims set endplay

[@jimsahm]

Great video Paul! Thank you.

[@drubradley8821]

On transfer cases like these 300's and the dinky 231's, having two shifter forks, does one of the shifter forks wear pad wear more then the other, meaning, the front driveshaft sides shifter folks get less, due to 4wd not being used except in time of need, for the common driver? Or, do the pads wear equally on both forks?

[@thomassawtelle7089]

Ever consider doing a GM NP205 and NP208 rebuild series? Thanks for another great video. Excellent content and detail.

[@GearBoxVideo]

www.5speeds.com/requests.html

[@jimsahm]

At 18:17...I am trying to punch out the pinion/gear and It will not budge... Tried a 4lbs hammer... it will not move... I did get the housing loose, but the pinion seems well stuck on there... should I try to press it out??

[@GearBoxVideo]

Bearing may have spun and seized on the pinion. You may have to heat the bearing and press it out

[@ozarksfarmerhansen8782]

Have to do a NP 205 for gran son have you any videos showing a complete rebuild. Thanks.

[@GearBoxVideo]

No I don't. Haven't had one in the shop in a long time

[@zanzibarbusiness]

Hi, thx for your great vid. I'm struggling with the one set screw..I put heat, shocked it, put more heat...Nada! Other one eventually came loose. I get close to stripping it but back off. Any advice?

[@GearBoxVideo]

If you strip the hex you may have to use one of those tools for stripped hexes and drive it in and try and shock and loosen the sit screw

[@zanzibarbusiness]

@@GearBoxVideo Great thank you.

[@flubdreload2818]

Have you ever considered doing a video on either a Tremec TR-3650 or maybe a Getrag MT-82?

[@GearBoxVideo]

Please see www.5speeds.com/requests.html

[@stevezickefoose8563]

Nice job!!

[@marcdejean817]

Hi Paul I like your video ....Excuse me if my question seems be stupid....I have change all bearings in my dana 300 but now I can't have 2 WD....4 low ,neutral and 4 high are ok... Can' you tell me what is the right position for the shift collars for having 2WD ? When we are in 2WD the front yoke must be free?

[@GearBoxVideo]

watch the video....carefully

[@danparden8103]

Very awesome video

[@celli351]

Please do a video on the T45 Transmission please!

[@GearBoxVideo]

www.5speeds.com/requests.html

[@evilmunky6223]

Hey Paul I was looking on the 5speed website for a rebuild kit for the borg Warner t45 do you know of a good place to get everything I need to rebuild? And also last time I had the tranny out had a lot of slop I think for the front shaft, what usually causes this and is there a way to fix without breaking it apart?

[@swampsnipe8790]

Serj Tankian is a mechanic now??

[@maldo72]

Which camera and mic setup do you use ?

[@GearBoxVideo]

There is a video on my channel that has my gear

[@maldo72]

@@GearBoxVideo cool thank you will check it out

[@chriscorum7266]

Im just changing the input shaft i dont have to disassemble all that i can just pull the allen bolts put gears on new shaft and replace correct?

[@GearBoxVideo]

It should pull out

[@shaun9480]

hi can you do a rebuild a g.m. m32 6 speed :) please

[@GearBoxVideo]

www.5speeds.com/requests.html

[@RobertKohut]

Nice!!

[@normanplombe2889]

Great video.

[@borgerpilots1949]

Paul, I am having an issue with a dana 300. would you be available for a phone call to ask a question? Sean

[@GearBoxVideo]

Write me in my email your question

[@cj5guy248]

Great video, I have a transfer case not sure if it's a Dana 300 or a Dana 20. I don't the year. One of the forks set screws is facing the opposite direction and I was wondering how you get to it to loosen it to get the rods out. The tag on the case is (309001-14) (5359121) If you know I would appreciate if you could let me know.Thank you

[@GearBoxVideo]

Watch my video. They are accessable with the right tools

[@shaun9480]

is a transfer box for 4x4 cars

[@RobertKohut]

This case is primarily found in Jeeps, but was also used in other 4x4 trucks like the Bronco.

[@johnrobinson357]

Yes and no. An all wheel drive " car " the transfer case may employ clutches in an attempt to keep wheel speed constant. With wheel speed read by the ABS sensors on the tone rings. Others use the brakes modulating the abs solenoids in a 4 channel system. Trucks mostly are offset front to rear ratio wise, 60 rear and 40 front. Or a mix of each. Again, ABS sensors can be used to read wheel speed. Still others claim all wheel drive with the transfer box doing the bulk of the work - subaru. However it is employed the transfer box takes a beating.

[@maldo72]

What part of mass are you from you accent gives you away lol

[@GearBoxVideo]

I'm not

[@maldo72]

@@GearBoxVideo was just messing with you I see that you are from nyc

[@GearBoxVideo]

Bingo... Da Bronx

[@maldo72]

@@GearBoxVideo lol from one new Yorker to anther lol lol great freakin channel so I am pretty sure you must have raced up on Fountainave back in the day.... only a new Yorker car guy would now that lol

[@MrConstant1]

Lmao!! These pearing knives...

[@kade426]

T176 video then Dana 300...someone's getting a like new cj lol.

[@MrConstant1]

Lmao! Pearing knives.