Twin Stick Dana 300

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This will be a modification that you can do at home, but you will need a torch and welder. You can farm that out to a machine shop for little cost.

All in all I have about $30 into this, including metal and hardware. If you took the welding and torching to a machine shop, they would probably charge you $20-$40, depending on what a minimum cost would be or how good friends you are. Luckily I have a hobby shop on base which cost me next to nothing to do this myself. I have seen these going for about $70-$100 on ebay and I know there are some manufactures out there charging in excess of $120 for this setup. The only bennies I can see with that is they give you the boot for it, but I believe you can even buy the boot separate from Currie Enterprises for around $30.

First is a listing of what you will need.

          

Click on highlighted part below for more information

     Qty      W         L        T

1. (2) - 1 1/4" x 5" x 3/8" flat stock

2. (4) - 3/4" x 3 1/2" x 1/8" flat stock

3. (2) - 1/2" x 2 1/4" x 1/4" flat stock

4. (2) - 1" x 5 1/2" x 1/4" flat stock

5. (2) - knobs

6. (2) - pieces of round stock

7. (4) - 1/4 x 3/4" bolts with nylon lock nuts

8. (2) - 1/4 x 1" bolts with nylon lock nuts

9. (1) -  1/2 x 2 1/4" bolt with nylon lock nut

10. (2) - Large washers for the above bolt

11. (1) - 5/8 x 2" bolt with nylon lock nut

12. (1) - Large nut for a spacer

Now once you have all the pieces you need to drill the holes. In piece number 4, you need to drill 2 holes in each piece. One 1/2" hole 3 1/4" up from the end and one 1/4" hole 1/2" up from the same end, both centered.

Once you have those holes drilled in number 4, you will need to bend the end with no holes in it at a 90 degree angle. You should have about 1 1/4" overhang, this is what you will weld the round stock too for shifters. Make sure you bend the round stock first for your application, I have a clocked Dana 300 so mine will be different from someone with a stock location. And too each his own. You also want to tap the round stock for the two knobs that you have. I just bought some generic black plastic ones for mine.

Now take number 3 and drill two 1/4" holes in it, 3/8" in from each side. Then you will need to twist these two pieces in the middle 90 degrees.

That takes care of the machine shop work the rest is all just drilling and what not.

With number 1, you will need to drill 3 holes in each piece. One 5/8" hole, 7/8" in on one side. The other side you will need to drill two 1/2" holes, one 1 7/8" in and the other 1/2" in.

For the last amount of drilling take number 2 and drill 4 holes into each piece. Each hole will be 1/4", the first hole drill 1/4" in from one side and from that hole drill 3 more 1" apart.

Most of these holes are there for adjustment of the twin sticks. Once you have it installed and in the jeep, you can fine tune it with these.

Now you can take your stock D300 shifting linkage off.

Don't forget to take out that plastic insert that the shifter bolt runs through.

Here is what it will look like when you get the linkage together, before you install it on the transfer case.

Here is some pictures of it installed on mine. I don't have it in the jeep yet due too I'm waiting on making a flat skid plate.

Side View Top View Front View

Final installation view.