D300 Rebuild

[Impact]

Hey Guys,

Does anybody have experience rebuilding a D300? I just have a couple questions... I'm sure I'll have more down the road...

1) Any tips when rebuilding it and trying to slid the center shaft through the gearset with all the loose needle bearings inside?

2) Is there a special way to get the shift rails out of the aluminum (I think) rail holder/front output assembly?

 

[Mlorint]

for the bearings use wheel bearing grease to hold them in place.

 

[dwcjwerfner]

I haven"t done one in years but I remember it as fairly easy, I think you need a press though. There is some really good guides online, I would have followed one of those.

 

[szabotage]

got lucky with mine and didn't need a press but did need bearing grease to hold the bearings together. if u were looking to access the detent ball ( its actually pill shaped) to get the twinstick, u need to really yank on the shifter forks or plastic hammer them out.the detent pill really holds them in place so a bit of force will get them free

 

[Impact]

for the bearings use wheel bearing grease to hold them in place.

Thanks!

I haven"t done one in years but I remember it as fairly easy, I think you need a press though. There is some really good guides online, I would have followed one of those.

I'm using the Tera Low instruction manual I found online... seems pretty good for info so far.

got lucky with mine and didn't need a press but did need bearing grease to hold the bearings together. if u were looking to access the detent ball ( its actually pill shaped) to get the twinstick, u need to really yank on the shifter forks or plastic hammer them out.the detent pill really holds them in place so a bit of force will get them free

The 300 already has a twin stick setup but I'm looking to replace the fork seals... The instructions I have say "Remove the two "pressed"detent plugs, switch, and threaded plug from the front bearing retainer housing"... That's where I'm kind lost. I just removed the whole assembly off the case with the shift forks still installed.

 

[jlalonde]

i just finished mine last week and used jb conversions 4to1 instructions. They have everything about the detents and pressed in plugs.

http://www.jbconversions.com/pdf/2307.pdf


I taped the three hole to 1/4 pipe thread. That way i didn't have to save the stupid plugs.

I dont have a press, so I cut all the bearing off. And was able to install the new one's by baking them in oven

Have fun!

 

[Richard]

This service manual may help, p. 2D-37 (I think it's the same one I used):
http://oljeep.com/gw/82_tsm/Part%202%20Section%20D.pdf

 

[Impact]

So... apparently I am completely out to lunch...

Any suggestions on installing the shift rails into the housing? Apparently the timing of the rails/balls/poppets is too much for me :banghead: I tried using the JB instructions where they say the rails should be placed at a certain measurement and then turned... but I don't feel like it's working.

Any tips?

 

[Impact]

Bump!

 

[dwcjwerfner]

What do you mean you don't feel like it's working. IIRC they were really tight when I first put mine back together ir was really tight but loosened up with oil and use.

 

[Impact]

Maybe that's all it is... They seem tight trying to move them once they are in the rail housing. I probably just need to suck it up put the entire 300 back together and go from there.

 

[dwcjwerfner]

Yeah I would say so, they really aren't that complicated, if you think it looks right when you put it together it probably is, there is quite a bit of friction there with all the gears dry as well as the inside of the seals where the rails go through as you probably had it all clean as hell with brake clean.