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Unread 01-18-2010, 06:21 PM   #1
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1981 CJ8 
Join Date: Dec 2004
Location: Reno/Tahoe
Posts: 1,665
Dana 300 issues help please

About a year ago my D300 momentarily popped out of gear while in low range going down a steep descent. Then never again. Just last Saturday however it happened several times on the Peavine run. Going forward under power up hill or level, it is fine, but descending a steep hill, etc using engine braking causes the T case to go BAM! and momentarily jump or slip a gear, then it holds in gear. It doesn't pop out into neutral, rather a sickening BAM sound and the drive train takes a very hard hit like it's not fully engaged, but it does stay in gear. I tried this in all 4 fwd gears on the T175 and no change.

The t-case lever is tight and feels like its properly engaged. It does not hit any sheet metal. I tried it w/ front hubs unlocked and it still did it. Went into 4 high and it did not happen-- back to 4 low range and then it happede-- tested and it repeated that several times. So the T case works fine in 4 high or 2 high but gets fussy in 4 low.

I know it is the T-case, since i experimented with different combinations of crawler box with T-case in and out. Not the tranny or R/P gears.

Preliminary research shows it can be: bent shift fork, bad or reversed clutch sleeve, bad selector ring or bad shift rail detent springs.

Before it gets all torn out of the rig, which is a PITA, any way to further isolate or verify the problem?

It only happens in 4 low descending a steep incline under engine brake.

Ideas anyone? The case is not clocked and is a single stick.


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RARECJ8 is offline   Reply With Quote Quick reply to this message
Unread 01-18-2010, 07:09 PM   #2
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1985 CJ7 
Join Date: Jun 2008
Location: Chicago area
Posts: 3,409
The highest probability is your detent springs. Novack recommends placing a washer for a #10 or 12 machine screw under them when you rebuild your T Case for this exact reason.
gmakra is offline   Reply With Quote Quick reply to this message

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