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Dana 300 popping out of 4L - is there a quick fix?

312 views 11 replies 7 participants last post by  devildog80  
#1 ·
Hi, I know this has been discussed numerous times, but I haven't found a definitive answer. The transfer case pops out of 4L, primarily when going downhill. I have the original single shifter and would like to keep it that way. The linkage seems to be fine, and I’m 99% sure the problem lies with the detent springs.

Is there a way to replace those without removing the transfer case from the Jeep? Could I just pull the shifter rails, replace the springs with stiffer ones, and then reassemble everything?
 
#2 ·
Or at least just new ones, not so much stiffer ones, as one might be broken?
 
#3 ·
4 Low all the time?

Need a "get by" for maybe a temporary way to stay in 4 low?

Can you "Bungee" the stick so it will stay in place until you can

dig in deeper?

I have no idea if that will even work.

Stay in 2 or 4 high and it won't bother you at all!

----JEEPFELLER
 
#4 ·
The first step is to insure the boot/shifter isn't contacting the body. This can be an issue with body lifts or the drivetrain has shifted.

Next, drop the inspection plate and insure the gears are moving all the way into their positions. Failure of the gear to move all the way can be from a worn or loose fork or an obstruction of the shift rail.

If everything looks correct, then you will have to drop the t case and disassemble it to get to the shift detents and springs.
 
#7 ·
Sir, I think you nailed it!
Removed the shifter boot and it stays in place now and won't pop out.
What's the long term solution? I do need the boot...
I tried to play with it - lower the contact point with the shifter, widen it a bit - and things did improve - it takes more time to pop out but still it does.

Any ideas?
 
#8 ·
Ain't that crazy!? It happened to me as well with a brand new boot. Somebody told me what I told you, and I didn't believe it. It was a revelation! I ended up cutting a slit in the boot, which makes it useless. It's a shame/disappointment that new parts are such low quality.

There is a link floating around for another brand of boot. I can't remember the name, but it's definitely NOT Crown/OA. Somebody will post it up before the day is over...
 
#9 ·
My original boot was torn completely through. I replaced it with a Fairchild one. The new one hasn't given me any problems but I just replaced it a year and a half ago.

Honestly the new boot was kind of a waste. The old boot looked a little ratty when the shifter was in low, but it also caused no problems!
 
#10 ·
Remove all of the body mounts

Slide the body forwards or backwards (whichever way works) to relieve the boot pressure on the stick

Then reattach the body to the frame.

This will probably be a task that will take a whole week.

Or

Maybe see if you can find a more rubbery, less stiff boot!

----JEEPFELLER :rolleyes:
 
#11 ·
I replaced both my Dana 300 and T5 boots with vinyl boots and bezels from Stronghold Shift Boots. The rubber after-market boots from both Crown and Omix-Aida are CRAP. They are way too stiff.
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owns 1985 Jeep CJ7
#12 ·
Some deerskin would look nice on there :)