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Transfer case swap Np208 to Dana 300

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Hitches31

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I may have a chance to get a Dana 300 with 4:1 ,w/ twin stick. I was thinking about swapping it into my 1986 K-5, 6.2 diesel, 700r4 tran, Np 208... I would like to step up to something stronger as my 208 is clunking. Can this swap be done in my k-5 ? Whould my drive shafts need to be shorten or lenghten? Custom crossmember?
 
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I found out this morning a few things about the Dana 300 is a passenger side drop, twin stick setup is by 4 wheel drive hardware, currently setup for a CJ-7 (T-176 trans)
 
Theres lots of Jeeps with 350's and th350's running full width axles with that case . Its a cast case , so thats stronger than a np208 , and Novak seems to think the thing will last if you change the output shaft to 32 spline .

Novak is 485.00 for the conversion to th700r4 , and 52.00 for the new output shaft . Add a 32 spline yoke and its cheaper than a doubler ( if you don't need to rebuild a rangebox and a 205 )

this one is already 4 to 1 , so I betcha its got goodies already :thumb:
 
The dana 300 has been rebuilt a few yrs ago. I was thinking about doing the Np205 but my trans was just rebuilt and I just dont have the money to build a np 205 and have the output swapped on the 700r4. I'm not going to be rock crawling of any kind . I'm currently running 10 bolt front with Yukon shafts, 7-560X Alloy USA u-joint, Lock Right Locker, GG 3.73 gears and Rear Corp 12 bolt, Yukon 30 spline Shafts, Eaton Posi Pro, GG 3.73.

As of now my low ratio is 30 (Crawl ratio) with using the np 208 and 47 (Crawl ratio) if I was to use the dana 300 with the 4.1


On the other hand If I fell into some cash I would like to to get a Atlas or Stak 2 speed box!
 
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Hitches31 said:
The dana 300 has been rebuilt a few yrs ago. I was thinking about doing the Np205 but my trans was just rebuilt and I just dont have the money to build a np 205 and have the output swapped on the 700r4. I'm not going to be rock crawling of any kind . I'm currently running 10 bolt front with Yukon shafts, 7-560X Alloy USA u-joint, Lock Right Locker, GG 3.73 gears and Rear Corp 12 bolt, Yukon 30 spline Shafts, Eaton Posi Pro, GG 3.73.
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you don't ahve to swap the tranny output shaft to run a 205, you just need a 27-spline input for the 205. Also 205's aren't that expensive to rebuild.
 
Why do you need a Dana 300 with the 4 to 1 in it if your not going to be rock crawlin:confused:, is there something wrong with the transfer case in there now
 
There is some clunking / banging in my 208 when I shift from R -> D or D to R.. Will the Chevy 205 bolt to a 700r4 using what adapter? The reason is I belive that my np 208 is starting to head South and I will soon have to replace. I found on a local 4x4 Fourm the dana 300 for sale for $700.00 and I was having a hard time trying to pass on the D 300..

I'm pretty much locked and have quite alot of recovery gear, MM-10,500 I don't need a deep gearing box but It would be nice to have! I have only used 4 L maybe a few time a year and It's always been enought but who know how this project will go (taller lift, bigger axles, and some bigger rubbers)
 
You can find a six round 205 ( front of case six bolts like your 208 ) with a slip yoke on a 80's 1 ton . Swap the input shaft to 27 spline .
 
pauly383 said:
You can find a six round 205 ( front of case six bolts like your 208 ) with a slip yoke on a 80's 1 ton . Swap the input shaft to 27 spline .
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85 and later to be exact. But you could use the older figure-8 style if it has the th-350 adapter. Then there is a small spacer you would need to get (about $40) to take up the extra length of the 700r4
 
IMO, the D300 is probably a strength upgrade over a 208 or 241. It has tons of aftermarket support (even an aftermarket case made by STAK that's supposedly really stout).

But, IMO, I would replace the 208 and call it good. If you don't need the gearing, don't bother with the D300. If you kill another 208 then start thinking about another t-case (besides, used 208's are worth what, $50?)
 
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