Got a bit of work done on it today.
Installed the front locker and set up the gears. It's so much quicker on a removable 3rd with carrier adjuster nuts compared to a Dana that also requires shims for carrier placement and bearing preload.. 12 in/lbs preload on the pinion bearings, pattern that's long and nicely in the middle of the gear face, 15 in/lbs carrier bearing preload and 0.2mm (8 thou) backlash. Strong, quiet and reliable setup.
Opened up the Dana 300. Bearings and gears look great so I'll throw some new seals in and be done with it. I removed the shift rails to remove the interlock pils for independent control of the front and rear output shafts. You have to remove the idler gear to get to the set screws that keep the shift forks on the shift rails. Not that bad of a job really. Also removed the shifter bracket from the front output bearing retainer for more clearance.
Got the 3rd member in the housing and threw the Longfields in.
-D300 with cover and idler gear removed
-cable twin stick shifter and billet D300 cover - cover should stop leaks and add to the case rigidity and therefore the gears strength
-Dana 30 axle next the Patrol chromo. The cross-sectional area is 32% more in the Patrol. Throw 4340 chromoly into the mix and the axle is theoretically over twice as strong.
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