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Unread 09-26-2012, 10:12 PM   #436
yellow_snocone
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Finally get to see it wheel sucks about losing fwd drive. Great build man LLLOOOTS attention to detail.

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Unread 09-27-2012, 04:17 AM   #437
Louie4
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Can't wait to see the pics.
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Unread 10-04-2012, 12:49 AM   #438
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Thanks gents...


FedEx dropped this off...

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Unread 10-04-2012, 06:16 PM   #439
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wow very nice! I just picked up a dana 300 and T5 to put behind my diesel swap.
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Unread 10-21-2012, 11:36 PM   #440
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Got started on the Stak build. Only a couple small gripes, for instance, the pitting on the case when I got it-



And Stak forgot to include the rubber o ring for the case halves. I had to make my own from my stash of extra o rings-


Other than that, it's a pretty good product and install so far. I had to shorten two bolts also but that's pretty minor. Just swap the guts and use their supplied parts.


Starting from a fully assembled and modified Dana 300 to the finished Stak case was about 6 hours. It's important to note that I also installed a fresh bearing set and had to first remove the existing bearings. I had a 20 ton hydraulic press, pneumatics, and a sturdy work bench.












I still need to fill it with gear oil after I preload the rear bearing. Then I'll need to either make new shifters or adapt my own shifters to this new setup. I'm leaning towards new shifters since I think it will be easier and more compact. I had to notch my crossmember a little bit but after that this new case will pay off.
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Unread 10-22-2012, 08:16 AM   #441
Louie4
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Flippin' sweet. How much did that case set you back?
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Unread 10-22-2012, 01:47 PM   #442
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Looks great. And great workbench area too. Might as well put new shifters in...
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Unread 11-20-2012, 02:37 PM   #443
gtxracer
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Quote:
Originally Posted by Louie4 View Post
Flippin' sweet. How much did that case set you back?
http://www.stak4x4.com/Dana_300/replace-a-case.htm

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Originally Posted by dayriesw View Post
Looks great. And great workbench area too. Might as well put new shifters in...

Thanks! I tried using the existing shifters this past week but it's looking like they won't work. Oh well. Time to call Stak.



Quick update:

As it turns out, my rear driveshaft has a 2.0" diameter. My blingin' front shaft is a 2.5" OD which means I should switch the application of the driveshafts. Instead, it would be easier to find another driveshaft with a 2.0" OD and cut it down or retube it. Combine this 2.0" OD driveshaft with a redesigned clutch slave cylinder relocation bracket and it will all clear.

I also installed some new bump stops that I got from Gavan. Thanks buddy! Finally got around to installing the Currie press-in style johnny joint into the hp30. The 1/2" bolt gives me a lot more peace of mind.

I also drove the Jeep today with the new case. Still need to configure the shifters but it drives smoother now. Still need to figure out why the front end pushes under hard acceleration while turning at slow speeds. Think trying to do a donut but the front end pushes through the corner instead of gripping the ground. I think it's the front shocks.

*sorry for the crappy cell shot, I'm upgrading my phone and camera soon*
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Unread 11-20-2012, 03:13 PM   #444
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I thought you replaced your RC shocks. Was that just in the rear? its been awhile since I've read your whole build thread
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Unread 11-20-2012, 04:16 PM   #445
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Yup, just in the rear. Thanks for reading!

Hoping to put some Fox IFP 2.0's up front as soon as I'm able...
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Unread 11-20-2012, 09:05 PM   #446
yellow_snocone
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Nice I look forward to see what you might fab up for those shocks
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Unread 11-21-2012, 06:09 AM   #447
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Looking good man.
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Unread 12-16-2012, 09:46 PM   #448
gtxracer
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Quote:
Originally Posted by yellow_snocone View Post
Nice I look forward to see what you might fab up for those shocks
More than likely some Fox 2.0s....or something along those lines. After the holidays of course

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Originally Posted by Imped View Post
Looking good man.
Thanks! Been eyeing your build too, wish we didn't have fender laws. I like the flare-less look.

****Time for an update with a dash of tech...****

Scored a XJ front driveshaft but it was too short to just chop down like I did for the rear. I noticed it was 1.75 OD and I had some scrap 1.75 and 1.50 tube so I sleeved it with 1.50 after cutting a relief notch and then sleeved the 1.50 with 1.75 to make it a .250 wall spare driveline. Its not completely centered but its balanced enough for me to do some crawling and slow speed wheeling. Total cost for me is $0 and I traded the shaft for some work on a buddy's rig.



Of course, plug welded then left a gap to fillet weld (I think that's the term).


Ground smooth


And painted up and ready to go
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Unread 12-16-2012, 09:54 PM   #449
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Then I extended my driver side bump stop since I didn't have time to make a new bracket to relocate the slave cylinder. I'll make sure to get pics and a write up when I do this since it will be much easier for others doing a TJ 4.0 np435 swap.

Enough of the tech, time for snow wheelin!




obligated poser flex shot


Started coming down pretty good and it was a ton of fun. Hopefully going again new years
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Unread 12-16-2012, 10:53 PM   #450
gst95dsm
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Great work man! That t-case is beautiful. Looking forward to some snow wheeling myself soon. Keep up the good work.
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