Advance Adapters 50-3021 User Manual

ADVANCE ADAPTERS INC. P/N: 50-3021

P.O. Box 247, 4320 Aerotech Center Way New Item: (12/01)
Paso Robles, CA 93447 PAGE 1 OF 3
Telephone: [phone] Fax: [phone] Page Rev. Date: 05-07-08

JEEP DANA 300 TO JEEP 21 SPLINE AX-5

ALSO: BA-10 AND AW4 (w/modifications)

KIT CONSISTS OF:

No. Qty Part No. Description

1. 1 51-8603 ADAPTER CASTING

2. 1 52-3021 SPECIAL 21 SPLINE DANA 300 INPUT

3. 1 716308 SEALED BEARING (716317)

4. 2 716517 GASKET

5. 6 723731 S.H.C.S. 3/8"-16 x 1"

6. 6 302069 STUD 3/8"-16 x 3/8"24

7. 6 302071 3/8"-24 FLANGED NUT

AX-5 INSTRUCTIONS:

This kit is designed to adapt the Jeep AX-5, 5-speed transmission to the Jeep Dana 300 transfer case and also as a rotation
kit for the Dana 300 transfer case.

This kit will allow you four rotation angles for the Dana 300 and proper spline engagement with little or no modifications.

A special long splined input shaft must be installed on the front of your Dana 300, replacing the stock input. The transfer
case input assembly must be taken apart to install the new input shaft. To do this, remove the six Allen head bolts on the
front retainer. There are two pry grooves located on the stock retainer. Use two pry bars into these slots to remove this
aluminum retainer. When the retainer is removed, you will find the drive gear, input shaft, and bearing on this retainer
assembly. By removing the snap rings on this assembly, these items will need to be taken apart. Once the items are
disassembled, you will need to set aside the stock roller bearing. A new sealed roller bearing has been provided to isolate
the gear box fluids. Install the new Dana 300 input shaft and secure by using the stock snap rings. Once this assembly
is assembled, you will then need to reinstall this retainer assembly back into your Dana 300 transfer case.

OPTION ITEMS:

Short D300 retainer P/N 716220

SPECIAL NOTE:

When rotating the Dana 300 to a higher
rotation, you may experience some
transfer case shifter interference. We
recommend that a twin stick shifter for
the Dana 300 be obtained to acquire
the necessary clearances.

The aluminum adapter plate must be rotated to line up the 6 counter sunk holes to the Dana 300. Use a gasket or RTV
blue silicone between these two components. Fasten the S.H.C.S. bolts with Loctite, securing the plate to the transfer
case.

Before bolting the two halves together, you MUST trial fit them together. Please
note that the majority of these installations will require the input retainer be
modified slightly. There is an allen type plug located on the back of the AX-5
transmission. A small amount of grinding is necessary to clear the plug. The
ground area measures approx. 1" long, and about 1/8" deep for sufficient
clearance. There may also be a small amount of grinding needed on the output
shaft. Please verify this when mocking the two together, and trim accordingly.

Once you decide on the rotation, install the six studs into the adapter ring (these
studs are a tight fit into the ring). Use a gasket or RTV blue silicone and fasten
the transfer case to the transmission adapter 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 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: 50-3021

P.O. Box 247, 4320 Aerotech Center Way New Item: (12/01)
Paso Robles, CA 93447 PAGE 2 OF 3
Telephone: [phone] Fax: [phone] Page Rev. Date: 05-24-05

JEEP DANA 300 TO JEEP 21 SPLINE AX-5

ALSO: BA-10 AND AW4 (w/modifications)

Things to consider during the installation are floorboard clearances and transfer case shifter handle location & clearance.
Since we have rotated the Dana 300 up higher than the stock rotation, the shifter handle may need to be bent for proper
fit. The other option is an aftermarket twin stick shifter for the Dana 300.

Due to the rotation of the transfer case you should add some additional oil to the transfer case to maintain proper oiling.

BA-10 AND AW4 APPLICATION INSTRUCTIONS:

Please note that the previous instructions are for adapting to the AX-5 trans. In
order to use the BA-10 and AW4, additional modifications are necessary. It is
highly recommended that this kit is purchased along with the new D300 input
retainer. This retainer has a shorter snout on it. This shorter snout will properly
clear the internals of the transmission. The original D300 retainer will work, but
a good portion of the retainer needs to be trimmed off of it.

Both of these transmissions have a
positive sick-out on the transmission
shaft. This means that the output shaft
will need more modifications than the AX-5. Please also pay very close attention
to the Peugeot transmission. This tranny has a bearing supporting the output
shaft. The new shaft sent in this kit WILL bottom out on that bearing if it is not
modified. An abrasive cut-off wheel does the best to get this done. Please trial
fit everything before bolting and siliconing them together. NEVER USE BOLTS
TO "SUCK UP" THE GAP! Please call Advance Adapters if there is anything
you are unclear on.

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.