DANA 300 TWIN STICK SHIFTER KIT
Contents
1. DANA 300 TWIN STICK SHIFTER KIT INSTALLATION OF SHIFT LINKAGEPIVOT Thread the 5 16 18 set screw into one of the pivot shafts Now insert the stud amp pivot shaft through the large hole in the shifter bracket and thread the second pivot shaft into the same stud and tighten see photo right Press a pivot bushing P N 403309 into both sides of both shift handles using a mallet Thread set screw into first pivot shaft insert into bracket and thread into second pivot shaft PRE ASSEMBLY Thread a 3 8 24 jam nut onto the 3 8 male heim joint and thread the heim joint into the bottom of the pivot block Now repeat for the second jam nut heim joint and pivot block IN VEHICLE ASSEMBLY 1 Reinstall the transfer case into the vehicle 2 Slide shift handles onto pivot shaft and CHECK FLOORBOARDCLEAR ANCE Depending on the rotation that you have the Dana 300 set to the handles may point to the passenger or driver s side of the vehicle It may be necessary to bend the shift handles close to the pivot block to get the shifter handles to point in the desired direction SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales2. ADVANCE ADAPTERS INC P N 403300 P O Box 247 4320 Aerotech Center Way New Item 1 04 Paso Robles CA 93447 PAGE 1 OF 5 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 12 3 14 DANA 300 TWIN STICK SHIFTER KIT KIT CONSITS OF Qty PartNo Description 403301 FRONT OUTPUT SHIFT RAIL NOTE This kitrequires one of the shift 403302 REAR OUTPUT SHIFT RAIL rails to be modified when using it witha 403303 SHIFTER BRACKET 4 1 low gear set We do not offer a shift 403304 PIVOT SHAFT rail with this modification already made 403305 HEIM JOINT LINK PLATE to it 403307 SHIFTER HANDLE 403309 PIVOTBUSHINGS Optional item P N303150AA 403310 3 8 FEMALE HEIM JOINT Aluminum shift knobs nee le ETR Sale Black Knobs with machined letters 302060 TWIN STICK SHIFTER BOOT 302061 FRONT SHIFT KNOB SHIPPED IN SHIFTER BOOT 302062 REAR SHIFT KNOB SHIPPED IN SHIFTER BOOT 302063 SHIFTER BOOT TRIM RING 303121 1 2 13 JAM NUT 722523 1 4 FLAT WASHER 723101 5 16 18 JAM NUT 723103 5 16 LOCK WASHER 723110 5 16 18x 3 4 S H C S 723151 5 16 18 SHOULDER BOLT 3 8 DIA x 3 4 LONG 723152 5 16 18 x 1 1 4 SOCKET SET SCREW 723719 3 8 24 JAM NUT 723755 3 8 16x4 S H CS 4 911341 3 8 SHIM WASHERS BUSHINGS ARE A PRESS FIT INTO THE SHIFT HANDLE BASE NOTE This assembly will require the installation of new shiftrails into your transfer case This kit allows the Dana 300 to be shifted to the following configurations 2WD High 4WD High 4WD Lo
3. Once the shift rails are in place continue on to the shift linkage installation Note that the original pivot location was cast into the front output casting and can be cut off for a cleaner looking installation This is necessary for some Dana 300 transmission adapters to increase transmission clearance 1 Bolt the shifter bracket 403303 to the front output casting using the supplied fasteners 723755 and 723110 Thread on the 3 8 24 jam nuts and 3 8 female heim joints onto the end of the shift rails Cut off this portion optional SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N 403300 P O Box 247 4320 Aerotech Center Way New Item 1 04 Paso Robles CA 93447 PAGE 3 OF 5 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 02 25 04
4. are vertical when the transfer case is in neutral and parallel to each other If the shift handles are not orientated properly unbolt the heim joint link plates and adjust the position of the female heim joint on the shift rail Use the jam nut to secure it in the desired position Reattach the heim joint link plates and check your results Shift the transfer case through the following configurations 2wd High 4wd High 4wd Low 2wd Low Rear Low and Front Low The shifter handles should not be closer than approximately 1 to the body in any of the shifter positions The frame and body will flex while driving and can cause the transfer case to pop out of gear or cause shifter binding if sufficient clearance does not exist Once the transfer case shifts properly and has sufficient body to handle clearance it is now time to fasten the shifter boot Insert the included boot ring into the shifter boot and slide the boot down over both shifter handles Determine the proper location for the boot Use self taping screws to fasten the boot and ring to the floor of the vehicle The last step is to thread the 1 2 13 jam nuts E _ TE eee a and shift knobs onto the shifter handles Notice parallel alignment of female heim joint and link plate SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or retu
5. cle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores
6. department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N 403300 P O Box 247 4320 Aerotech Center Way New Item 1 04 Paso Robles CA 93447 PAGE 4 OF 5 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 10 11 04 DANA 300 TWIN STICK SHIFTER KIT Check that the existing hole in the floor will be large enough for the new shifters If additional room is needed cut grind the hole in the floor to the correct shape Be careful not to cut the hole too large so that the shift boot ring will no longer cover the hole Now you may paint the shift handles the desired color Take care not to get paint onto the pivot bushings because paint may cause a tight fit or binding Slide a shifter handle onto a pivot shaft with the handle offset pointing outward followed by the included 1 4 flat washer 5 16 lock washer and then fasten with a 5 16 18 nut Repeat for the second shifter handle Fasten the female shift rail heim joint to the male shifter handle heim joint using the 3 8 shim washers shoulder bolts heim joint link plates and 5 16 18 nut Repeat for the second shifter handle Now check to verify that the handles
7. g on to the remaining instructions The following is a general guide that outlines how to install the new shift rails included in this kit Refer to a service manual for specifics on replacing shift rails It is necessary for the transfer case be removed from the vehicle for the required disassembly While not required for the installation of this kit rebuilding the Dana 300 while it is apart may be a good idea if it has not been done recently We offer a Dana 300 rebuild kit under Part No 400300 Remove the Dana 300 pan Unbolt the cluster shaft retainer and press out the cluster shaft Remove the cluster gear making sure to not misplace any of the loose needle bearings Remove the set screws out of both shift forks Carefully remove both shift rails out the front of the transfer case being careful not to misplace the balls and springs Before you set the shift rails down mark them for identification DO NOT REMOVE THE INTERLOCK PILLS If the interlock pills are removed the transfer case will shift into Low and High at the same time and transfer case damage will result Using the specific information in the service manual install the new shift rails into the correct location Refer to the old shift rails to determine which is the front and which is the rear USING BLUE LOCTITE reinstall the shift fork set screws Reinstall the cluster gear needle bearings cluster shaft cluster shaft retainer and pan INSTALLATION OF SHIFT LINKAGE
8. rn privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N 403300 P O Box 247 4320 Aerotech Center Way New Item 1 04 Paso Robles CA 93447 PAGE 5 OF 5 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 07 16 07 DANA 300 TWIN STICK SHIFTER KIT 403302 L 403303 N 403310 2 PLCS 403307 2 PLCS 4 PLES 403305 P amp gt X g 2 g x i i l 1 403311 2 PLCS SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehi
9. w Rear Low and Front Low Refer to the exploded assembly view on the following pages for part identification and part assembly p CHRHNADNAPWNE Z 1 1 2 4 2 4 2 2 2 1 1 1 1 2 2 6 2 1 4 1 4 2 This is a universal type kit that may require the handles to be bentforspecific applications Transfer cases kept with a stock rotation will require the shifter handles to be bent SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N 403300 P O Box 247 4320 Aerotech Center Way New Item 1 04 Paso Robles CA 93447 PAGE 2 OF 5 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 02 25 04 DANA 300 TWIN STICK SHIFTER KIT INSTALLATION OF SHIFT RAILS PARTS 403301 amp 403302 The new shift rails must be installed before continuin
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