I have been rebuilding my dana 300 for a while now and have ran head first into ever obstical I could. Here is were I am at now...
Between this rear inner bearing and the big gear on the shaft, there is a thrust washer. The thrust washer seats against the shoulder on the shaft, and the bearing seats up tight to the washer. I pressed the rear inner bearing up as tight as it will go and the big gear still moves alittle. I messured the slop on the rear inner gear and it is close to 10 thousands of an inch. My friend said that this is becuase of wear over the years and says the only way to correct this is by adding a 10 thousand of an inch shim in between the thrust washer and the rean inner bearing. I am just not sure. If anyone knows anything about this and can help me out here please do. I need to go ahead and get past this. I have dana 300 parts all over my shop and can't do anything else until I get this done.

Thanks,
Daniel

Mine was about the same Daniel. There is supposed to be a gap as the gear spins on the shaft, but yeah, it does sound excessive. A few thou is plenty I think. My t-case made an annoying loud grating rattle when coasting at speed. Not under power, but not so light on the throttle as to be decelerating. I think it's these big gears rattling back and forth when there is no thrust one way or the other to keep them in place.

I think your case may end up giving the same rattle. If you're going to shim it, putting a shim between the washer and the gear is not a good idea. The gear spins on the shaft and a shim a few thou thick up against it won't last long.

What I suggest is to machine the thrust washer. Put it on a lathe and bore out a recess on the side that seats against the shoulder on the shaft. Just big enough in diameter to clear the shaft shoulder and deep enough to take up some of the slack. Then, put the shim bewteen the washer and the bearing. If you bore it 5 thou deep for instance, put a 5 thou shim between the washer and bearing and the bearing will still be sitting where it needs to be. (Actually, even this probably isn't needed. If you've got at least 5 thou in shims at the end of the shaft, you could take some out there to compensate instead.)

Check your front output too. The big gear will likely have as much slop on that one as well. That one's a bit harder to fix though as there's no thrust washer.

--Dan

Thanks Dan.

I am still working on that darn case. I think it is trying to get the best of me. I still can't seem to get the shims right for some reason.
On a side note here. I order my front leafs from Matt yesterday. Also order 1410 yokes for the dana 60 front axle and the 14 bolt rear. I got my disc brake brakets in the other day and will wait to have the axles regear before I add the extra wieght of the brakes on them.
Still waiting for my doubler kit to come in.

Now back to the shop to go at that darn t-case again...

Later,
Daniel

I am outside working on taking the computer and cruise controll out of the trooper. I have the cruise out and most of the computer. The trooper had the 2.8 chevy in it and I wire it all up when I swap the the 2.3 out and put in the 2.8.
Does the computer run anything else other than the engine? All the wires go right to the engine except on big one big wire clip. I am hopping It just goes to the gauges. If so I can just disconect that clip and leave the rest of the wires. If anyones knows about this please help a brother out here.

Thanks,
Daniel

What happened to the 4.3 you were going to use?

Yes as of NOW I am going to be using the vortech 4.3. The last swap I did in the trooper had the 2.8. I am talking about the computer to the 2.8 .

Later,
Daniel

Ahh. I didn't think you would've gone to all the trouble with the tranny and 4.3 engine to ditch it.

Here is the wirring harness that I am talking about. This is the side that conects to the computer.

Here is the side that conects to the motor.

Here is the only plug that conects to the wiring harness under the dash. I hope it just goes to the gauges but I am not sure. If anyone can knows anything about what this clip controls please post up.

Here is my new RANCHO - 44044 WAGONEER FRONT SPRINGS from MATT. Thanks again <img src="/forums/images/graemlins/wink.gif" alt="" />

This is a shot of what it looks like hanging under the trooper.

Here are a few shots of the trooper. I mounted it bak on the chassie and hope to start to tack everything in place. Then I will take the body off one last time and weld everything up tight and paint the chassie.




Later,
Daniel

Well I don't have the 2.8 so I can't help on the harness, I know my plug to the gauges isn't blue.

Looks as if you are making some good progress.

That thing looks realy good man!!!!! I like how black the top half is, You can't even see the windows <img src="/forums/images/graemlins/smile.gif" alt="" />. That plug looks like it has more wires then what the gauges take, there might be some wires for the warning lights and things like that. I'll take a look at mine, and try to help ya how alittle more. <img src="/forums/images/graemlins/kewl.gif" alt="" />