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NWF Blackbox-i to Dana 300 
______________________________________________________________________________ Step 1: 1. Drain DANA 300 by removing drain plug on underside of case (1/4” Allen key ) and dispose of fluids appropriately.  ______________________________________________________________________________ Step 2: Remove (6) Socket cap screws (3/8” Allen key) securing the input bearing retainer to the case.  _______________________________________________________________________________ Step 3: Hit the input bearing retainer with a rubber mallet to loosen from case   _______________________________________________________________________________ Step 4: 4. Once you have room, use a small pry bar to separate input bearing retainer from Dana300 case  _______________________________________________________________________________ Step 5: Place removed input bearing retainer down on a flat clean surface, and remove snap ring using GOOD snap ring pliers. Put it aside as we will be using it later. This allows us to remove the input gear drive from input shaft.   _______________________________________________________________________________ Step 6: Un-pack your NWF BlackBox-i shipment. You will find your Blackbox-i pre-assembled as one unit. Looking at the input side of the case( which looks like the clocking ring ), remove the 6 Allen keys that hold the unit together. The case may seperate into 2 peices at this point. If it does not, using a 3/16" allen key, turn the 3 socket set screws clockwise, which are sunk into the input side of the blackbox-i. After they seperate, turn the allen key counterclockwise all until the socket set screw seats back in the blackbox-i lid. 
_______________________________________________________________________________ Step 7: Clean the Dana300 input gear removed in step 5 and install it on the output side of the blackbox-i base. Follow this with the snapring removed in the same step. 
_______________________________________________________________________________ Step 8: Install the (6) 7/16" Socket Set Screws into the inner cirle of the backside of the Blackbox-i Base. 
_______________________________________________________________________________ Step 9: Apply a thin layer of Gasket sealant to the backside of the blackbox-i and Carefully slide the blackbox-i into the Dana 300 case. Because the holes of the Dana 300 case are not uniform, the blackbox will only go onto the Dana 300 in a specific rotation . Line up all 6 holes and apply cases together. 
_______________________________________________________________________________ Step 10: Fasten the Blackbox-i to the Dana 300 case by using the (6) 3/8" x 2 1/4" Socket Cap Screws and 3/8" Nordlock washers. 
_______________________________________________________________________________ Step 11: Position yourself infront of where your BlackBox-i is going to mount on your transmission ( or transmission adapter if not directly compatable). Using a caliper, measure out the distances between holes. You will find one distance is larger than the others. Mark this position. _______________________________________________________________________________ Step 12: Repeat step 21, this time locating the largest distance between adjacent mounting holes on the blackbox. As you would assume, the 'wide' part of the blackbox-i must join to the back of the 'wide' part of the transmission. _______________________________________________________________________________ Step 13: Apply a thin bead of gasket sealant around the lip of the blackbox-i where the two 'halves' of the blackbox join. With the orientaion you determined in step 22, join the lid of the blackbox-i to the base of the Blackbox-i assembly using the supplied 3/8" x 3" Socket cap Screw so that the output of the Dana will be approximately where you want it. 
_______________________________________________________________________________ Step 14: Using a transmission jack, position the assembled Blackbox-i/Dana300 behind your transmission. Make a notation on where the studs need to be placed in the blackbox-i to line up with the holes on the back of the transmission so you get your ideal clocking for the front output of the Dana 300. Once you determine where one stud is to be threaded into the blackbox, the other 5 are positions uniformly around. ** If you are using an adapter on the back of your transmission to mate the blackbox - it may be easier to take it off the transmission and position it on the blackbox as a reference first. 
Thread the coarse thread into the blackbox-i by first locking two 3/8" NF nuts together on the stud, and turning the top nut with either a 9/16" wrench or socket. _______________________________________________________________________________ Step 15: The blackbox-i is shipped with (3) brass 3/8"NPT plugs. Remove the one that is orientated closest to the top. Tighten the 2 remaining brass plugs into the case. _______________________________________________________________________________ Step 16: Fill the Blackbox-i with 3/4 Quart of 80/90w via the plug that was removed in step 15. Now thread in the supplied brass breather fitting into the same the same hole. Extend the breather by attaching a rubber hose ( not included )to the breather fitting and clamping it. A good place to route it is up to the top of your engine bay. Fill the Dana300 to OEM Spec. _______________________________________________________________________________ Step 17: Install the Cable Shifter onto the Blackbox-i. The instructions to do this are found back in the Blackbox Tech Section. _______________________________________________________________________________ Step 18: Reposition the assembly behind the transmission and fasten down with the (6) 3/8" NF Nuts on the studs installed in Step 4. _______________________________________________________________________________ Step 19: You are required to fabricate a crossmember which properly supports the Dana300/BlackBox-i assembly. Failure to do so could result in broken parts on your Blackbox-i, Dana300 transfercase, and drivetrain. _______________________________________________________________________________ 
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