Advance Adapters 50-0432 User Manual

ADVANCE ADAPTERS, INC. P/N: 50-0432

P .O. Box 247, 4320 Aerotech Center W ay New Item: (06/06)
Paso Robles, CA 93447 PAGE: 1 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 05-20-08

GM 4L60E 4WD HEX BOLT PATTERN

TO DANA 300

KIT CONSISTS OF:
No. Qty. Part No. Description

1. 1 300619 SENSOR

2. 1 51-0405 CASTING

3. 1 51-9111 CASTING

4. 1 52-0432 DANA 300 INPUT SHAFT

5. 1 716074 RELUCTOR RING

6. 1 716079 PLUG

7. 1 716308 BEARING (#6209)

8. 1 716511 "O"-RING

9. 1 716517 GASKET

10. 1 716749 NATIONAL SEAL 471870

11. 4 720011 10mm X 1.5 NUT

12. 4 720061 10mm-1.5 X 50mm STUD BOLTS

INSTALLATION INSTRUCTIONS:

This kit is designed to use a stock 4L60E 4x4 hex bolt pattern transmission to a Dana 300 transfer case. If you do not have
the 4X4 version of the 4L60E, you will have to purchase a new GM output shaft. To assemble this adapter, you will have
to modify your output stickout from the back of the transmission case. The proper cut off length is 4.10". This measurement
should be taken from the rear of the transmission case.

1. Starting at the Dana 300 transfer case, remove the 6 socket head bolts from the aluminum index hub on the front side
the transfer case.

2. Using the two slots on the side of this retainer, you will need to pry the retainer out of the transfer case. This retainer
assembly does pilot into the rear output shaft of this transfer case. If the retainer assembly seams tight to remove, try
spinning the rear output shaft.

3. Once the retainer is removed you will need a pair of snap ring pliers to remove the snap ring that retains the drive gear
to the input shaft. Remove the snap ring and the drive gear from the input shaft. The aluminum retainer should now
have the bearing, input shaft, seal, and a snap ring holding the bearing into the retainer. This snap ring must also be
removed to allow the bearing and input shaft to be pressed out of the index housing.

4. The seal will also be required to be pressed out of the index retainer. The retainer should now be empty.

5. Install the new bearing onto the new input shaft. Install both components into the stock retainer and install the stock
snap ring.

6. Install the input drive gear onto the input shaft and retain it with the stock snap ring. Make sure the gear is installed
so that the cogged side of the gear is facing away from the bearing.

Optional items:
716055 Mount

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the 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 vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0432

P .O. Box 247, 4320 Aerotech Center W ay New Item: (06/06)
Paso Robles, CA 93447 PAGE: 2 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 06-22-06

GM 4L60E 4WD HEX BOLT PATTERN

TO DANA 300

7. Install the new seal provided in the kit - the open side towards the transmission.

8. Apply Loctite 515 or equivalent sealant to the retainer surface and install into
the Dana 300 transfer case. Make sure the pocket bearing is installed in the
Dana 300 output shaft

9. Bolt retainer to the transfer case using the stock bolts. Torque to 10 ft./lbs.

10. This kit fits the 4L60E 4WD transmission only. The stock 4WD output shaft
must be shortened to a stickout of 4.10" from the rear of the transmission.

11. Install the adapter to the 4L60E using the metric bolts and lock washers. Make
sure you install the square o-ring between the adapter and the transmission.

12. The transfer case should be test-fitted to the adapter to check for shaft
engagement. Make sure the transfer case fits flush up to the adapter surface.
If not, check for burrs on the shafts and/or output shaft cut off length. Never pull the transfer case to the adapter

using the bolts to draw these components together.

13. Install a silicone sealant on both sides of the gasket and install the transfer case to the adapter. Note: The gasket will
only fit onto the transfer case in one rotation.

14. Install the nuts onto the new stud bolts and Loctite to secure.

(illustrated in photo right)

.

If for any reason the two bolt surfaces do not slide together, DO NOT FORCE OR PULL TOGETHER with the bolts.
If you have any questions, please call 1-800-350-2223, for technical assistance.

New input shaft & stock parts assembled.AA shaft & bearing with stock parts

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the 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 vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0432

P. O. Box 247, 4320 Aerotech Center Way New Item: (06/06)
Paso Robles, CA 93447 PAGE: 3 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 06-21-06

GM 4L60E 4WD HEX BOLT PATTERN

TO DANA 300

TRANSMISSION INSTALLATION INFORMATION:

Cut the output shaft so that it has a stick out of 4.100" from the rear of the main transmission case. Install the new reluctor
ring with the set collar side going on the shaft first. Before tightening this clamp, trial fit the 51-0405 adapter plate onto
the back of the 4L60E transmission. With the adapter set on the back of the transmission, install the 300619 reluctor sensor
into the adapter casting. The 300619 sensor should line up over the teeth of the reluctor clamp. When you obtain this
location, remove the adapter housing, making sure not to disturb the position of the clamp on the shaft. With the clamp now
exposed, tighten the two set screws on the clamp. Loctite on these set screws is recommended.

Trial fit the 51-0405 adapter and 300619 sensor back on the transmission and make sure the reluctor ring teeth and sensor
still line up properly. RTV Blue Silicone should be used to seal the 51-0405 adapter to your 4L60E transmission. Screw
the 300619 sensor completely into the 51-0405 casting. With a feeler gauge, check the gap between the sensor and the
reluctor ring. This gap should be around 0.010" to 0.012". Once 0.010" to 0.012" clearance is obtained, loc-tite the sensor
into position.

Sensor note: This sensor will match up with the GM pigtail P/N 12162193 or Carquest P/N TX3A.

Once the 51-0405 is installed, install the 4 metric stud into the this adapter. Install the o-ring gasket on the 51-9111 adapter
and bolt it to the 51-0405 casting. Note the output shaft on the transmission should be flush with this (51-9111) casting after
it is installed. The stock Dana 300 studs should be retained to install the transfer case to the new adapter kit. The casting
has two rotations options, however only the higher rotation should be used due to shift rail clearance.

This transmission installation will require slight transmission pan modifications and will require the drivetrain to be offset
1" to the drivers side. Some applications may require a smaller diameter drive shaft.

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the 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 vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0432

P. O. Box 247, 4320 Aerotech Center Way New Item: (06/06)
Paso Robles, CA 93447 PAGE: 4 of 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 06-21-06

GM 4L60E 4WD HEX BOLT PATTERN

TO DANA 300

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of
the components will void any possible warranty or return privileges. If you do not fully understand the 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 vales,
wiring diagrams and other related equipment. These manuals are normally available at automotive dealerships and parts stores.