Transfer Case
1983 Dana 300
Approach
I decided to preserve the stock Dana 300 transfer case. It is, as Motor Trend writes, “one of the most significant transfer cases ever developed and sits high atop the list of bulletproof transfer cases.” What’s more, the “Dana 300 has exceptional strength for it’s size” and “can easily handle power ratings up to 350 horsepower and 350 lb-ft of torque.”
As far as I could (non-expertedly) tell, my stock Dana 300 was in good shape. Assuming it’s original — and I have no reason to believe it’s not — the case had about 133,000 miles on it when I rebuilt it. The case was extremely dirty on the outside, but the fluid was clean, the gears shifted and meshed beautfiully, and I didn’t find any sludge or metal shavings/chips inside.
My Dana 300 presented the following numbers:
Rear output housing: C300-19-15, 8/23/82
Case tags: SER. NO. 224902, 309007-1, 5361994
Case: C300-15-2
Front output housing: C300-19-5
Key parts
| No. | Part | Part No. | Link | Manufacturer |
|---|---|---|---|---|
| 1 | Dana 300 master rebuild kit | CWA-D300MASKIT | Summit Racing | Crown Automotive |
| 2 | Dana 300 twin stick kit | ADD-403300 | Summit Racing | Advance Adapters |
| 3 | 4WD/lockout indicator switch | J3211322 | Summit Racing | Crown Automotive |
| 4 | Shift rail detent ball plug | 233857147242 | eBay | N/A |
| 5 | Speedometer cable | CWA-J5351777 | Summit Racing | Crown Automotive |
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Instructional videos
Tear down
Recommendation 1
Gear Box Video: Dana 300 Transfer Case Rebuild - Part 1 - Tear Down
Recommendation 2
UCanDoIt2: Dana 300 Rebuild 1 of 4
Alternative approach
Advance Adapters produces the Atlas transfer case, which they will custom build specifically for your rig — gear ratios, input splines, etc.
eBay offers several fully rebuilt Dana 300 cases, including this example with Novak Conversions parts.
Technical notes
Different length output housing assemblies
Dana 300s from 1980 have a shorter rear output housing. According to Novak, they measured 3.5'“ — compared to 5.5” for 1981 and later cases. Novak states, “These [shorter] cases may have a Jeep number #5361332 or the tailhousing may have a casting number of #C300-15-2.
If you’re rebuilding a Jeep CJ7 and plan on a taller lift, the shorter output housing could help with driveline angles. (This isn’t as much of an issue for my CJ8, which has a longer wheelbase.)