Kit 135, adapting TH350 transmissions (4wd style) to the Jeep Dana 300 transfer case632.00

Kit contents:

• Adapter housing
• Transfer case input shaft, 27 splines
• Seal
• Gasket
• Seal ring
• Fastening hardware
• Steel base mount foot
• Instructions

Kit 135-S, adapting TH350 transmissions (2wd version) to the Jeep Dana 300 or Jeep NP208, 219, 228 o644.00

Kit contents:

• Adapter housing
• Transmission output shafts, 23 splines
• Seal
• Gasket
• Seal ring
• Fastening hardware
• Steel base mount foot
• Instructions

Strength Comparison of 27 vs 23 Spline Versions

The 27 and 23 spline shaft sizes are quite comparable in minor diameter (the diameter of the shaft at the root of the splines) and therefore, strength. Diameters are very close and the finer 27 spline vs the coarser 23 spline has shown no significant strength variation. The E4340 (similar to 300M) material used in production of the Novak shaft is of a superior strength both in PSI yield and torsional resistance - which is exactly the type of load these shafts see. Aside from that, fundamental design strengths are comparable.

GM 27 spline and Jeep / Dodge 23 spline shafts have a history of great strength in factory applications and Jeep aftermarket set-ups.

Mount, rear, transmission, polyurethane, Jeep, Novak style

This rear mount bolts direct to your Novak adapter, and can be used with a variety of crossmember styles.

Mount, rear, transmission, polyurethane, Jeep, Novak style39.60

Shaft, output, TH400 transmission, 4wd, 32 spline, 6”, 1982-1998

Turn your 2wd TH350 into the 4wd version with this good used factory output shaft.

Shaft, output, TH400 transmission, 4wd, 32 spline, 6”, 1982-1998212.50

Cooler, auxillary, transmission, 29,200 BTU (HD recreational), 1 ½” NPT fitting

For every 10 degrees cooler you can keep your automatic, you add 25k miles to their life. This stacked plate style cooler is both rugged and efficient, and it's flanges make it easier to set up than other styles of cooler. See related cooler lines, adjacent.

Cooler, auxillary, transmission, 29,200 BTU (HD recreational), 1 ½” NPT fitting152.00

Kit, automatic transmission cooler lines, braided stainless, 2 lines, 74” OAL ea, -6AN female threa

Tough, flexible stainless lines with easy sealing AN fittings. We've installed these on so many Jeeps and they're an in-and-done type product and compatible with our #OC-H7B cooler, adjacent.

Kit, automatic transmission cooler lines, braided stainless, 2 lines, 74” OAL ea, -6AN female threa149.76

Gaskets & Rebuild Kits for Dana 300 Transfer Cases

Replace the hard-working bearings and intermediate shaft of your Dana transfer case with one of these kits, all while sealing it up and getting your bearing endplay correct. See them and several other parts and kits here for your Dana 300.

Kit D328-D, billet aluminum bottom cover pan, Dana transfer cases, deep version

A deep and rigid billet aluminum pan for your Dana 300 transfer case. More fluid capacity, better sealing and some anodized eye candy for your geartrain. Shallow version for better ground clearance also available here.

Kit D328-D, billet aluminum bottom cover pan, Dana transfer cases, deep version174.00

Kit, Dana 300 front output rear bearing billet cap

This innovative bearing cap uses o-ring sealing around its perimeter and bolt holes, then shims the bearing internally, instead of the leaky, exposed stack-up shims. This is one way Novak builds its own leak-free Dana 300's in-house.

Kit, Dana 300 front output rear bearing billet cap87.70

Kit, shaft, input, bearing w/retainer, preassembled with proper bearing preload

If you are uncomfortable setting up the input on your D300 or simply would like our stronger billet retainer and all new components pre-set for your transfer case, this is the perfect solution. This kit includes our billet D300 input retainer, new snap ring, bearing and seal all assembled to the included Dana 300 input shaft as part of the #453 kit.

Kit, shaft, input, bearing w/retainer, preassembled with proper bearing preload278.45

Dana 300 Super Short Tailshaft Assembly, #300RX

Strengthen and shorten your Dana 300 in one shot with Novak's #300RX tailhousing assembly. The factory output shaft is the Dana 300's fuse, and the upgrade to 32 splines and an improved driveshaft angle will make a serious difference. See it here.

Shaft, input, Dana 300, 23 spline extended depth splines, factory length

Some factory 300 input shafts have excessively worn splines. This extra hardened replacement is an upgrade in materials and design, featuring extended splines to maximize the connection to your 23 spline output shaft 700R4 kit above.

Shaft, input, Dana 300, 23 spline extended depth splines, factory length229.00

Arm, pivot, shifter, Hydramatic 350, 400, 700, 4L60E & 4L80E Lokar, fully adjustable

This is the arm we reach for when setting up a shifter linkage to a GM automatic in a variety of Jeeps. The adjustable bellcrank gives the installer the freedom to set the proportion of throw to the same as the shifter in the Jeep, be it a column or floor shifter.

Arm, pivot, shifter, Hydramatic 350, 400, 700, 4L60E & 4L80E Lokar, fully adjustable78.00

Shifter kits, Dana 300 twin stick

Shifter upgrades are frequently done with a transmission swap. See our options for shifters, boots and knobs for your Dana 300, here.

Boot, twin-stick, textured, with stainless steel bezel

Choose this boot to use with the adjacent Dana 300 twin stick kit.

Boot, twin-stick, textured, with stainless steel bezel29.25

Cover, transmission tunnel, CJ & YJ style, customizable

Start with a clean slate tunnel cover for your 1976-1995 Jeep CJ / YJ floor. Cut your shifter holes and install boots onto it as required. Material is aluminum. Can be painted. More info here.

Cover, transmission tunnel, CJ & YJ style, customizable48.80

TH350 Transmission Package, Turn-Key

Sourced, remanufactured and built in-house to Levels I, II or III. We then dyno test them, and profesionally package and deliver it to your location, adapted and ready for installation. See and order one here.

Also available as part of our popular Turn-Key powertrain program.

Installation Requirements

Tools

Tools required will vary depending on which kit is selected. The automatic transmission takes more specialized tools and knowledge,gaskets, seals and snap ring pliers, etc. The D300 input will require bearings be pulled and pressed on the input, in additionto typical mechanic's hand tools.

The automatic transmission takes more specialized tools, knowledge, gaskets, seals and snap ring pliers, etc. Transfer case input installation takes normal tools along with some larger snapring pliers. Installation after the output shaft or input gear isin place requires normal mechanics tools.

Powertrain Placement

As these usually are installed as part of an engine swap setting the powertrain to the proper pitch angle is recommended - usually tilted down ~5 (3-7 acceptable) degrees. Offset will be to the right (passengers’) side because of the driver drop transfer case and front differential (usually 1 to 1-1/2”). Consult our engine conversion guides for more specific recommendations on placement if the engine is being replaced.

Clocking Information & Driveshaft / Yoke to Pan Clearance

Use of the factory size driveshaft and yoke is recommended. Our adapter design has maximized clearance between the transmission pan and yoke, but it is necessary that you install your GM engine offset 1-1/4" to the driver's side. If you are installing against a factory AMC engine with our 437-AMC adapter kit, your factory engine should already have this proper offset. Our adapter is drilled for multiple clocking locations from near-factory (20 degrees down) to near-flat (3 degrees down). However, pan clearances and front axle width may inhibit the flatter options.

Engines & Engine Mounting

Engine placement in these Jeeps should consider the following points:

• Left-right offset location is similar to factory at ~1-1/4" to the driver's side
• Avoid installing the engine too low (axle clearance and other issues)
• Avoid installing the engine too high (transmission tunnel interference, etc.)
• Set your engine to 4-7 degrees of tilt rearwards, like the factory engine & powertrain
• It is usually best that Chevy and Gen III+ V8 engines install approximately 3" further forward, using the back of the engine block face as the datum
• When mocking up your engine installation location, pay special attention to radiator and fan clearance.
• Firewall modifications are not expected.

Novak engine mounts are available to ease the installation of your engine.

Novak's engine mounts, feature vibration dampening, superior strength and useful adjustability - adjustable even after the engine is installed. The design, strength, and affordability of our mounts are second to none.

Novak Gen III+ engine mounts for 1976-1986 Jeep CJ models will remove any guesswork from the engine installation location as they are predetermined for the best location and engine clearance margins.

Driveshafts

Driveshaft length changes may be required. Chevy engines (with their rear distributors) can install around 3" further forward than AMC engines. It is also recommended that LS family engines be installed 3" further forward than the factory block (using the back face of the block as the datum point) for exhaust clearance, firewall access, etc.

Because of the engine placement and transfer case SYE kits are frequently installed with many of these conversions, you may end up with a longer rear driveshaft (very desirable for lifted Jeeps) and a shorter front driveshaft.

Some installers, concerned about the expense of new or modified driveshafts, attempt to let the existing driveshafts dictate engine, transmission and transfer case location, often to the detriment of the project. Our recommendation is to prioritize the correct position of drivetrain components over saving a few dollars which is usually regretted in the long run with compromised positioning.

Jeeps that require extensive travel or specialty-built driveshafts have this option available through several fabricators across the nation. These are normally specified after placement of the new transmission and measured at vehicle ride height. As the rear driveline gets shorter, it is often advantageous to us a Double Cardan or “CV style” rear shaft with the correct geometry at the axle to minimize vibrations and possible binding.

Axles

Use of factory axles is completely acceptable with this conversion. Axle upgrades are not necessary, but they may bechosen for reasons external to this transmission upgrade.>

Also See

• Adapting the TH350 to the Jeep Model 300 Transfer Case - short version
• Adapting AMC I6 & V8 Engines to the Chevrolet / GM Hydramatic Transmissions
• Complete TH350 Transmission Package
• Parts for the Dana Model 300 Transfer Case
• Dana 300 Transfer Case Twin-Stick Shifter Kit
• Dana 300 Ultra-Short HD Rear Output Assembly
• The Novak Guide to the GM TH350 Automatic Transmission
• The Novak Guide to the Dana Spicer Model 300 Transfer Case