Advance Adapters 50-5915 User Manual

ADVANCE ADAPTERS INC. P/N: 50-5915

P.O. Box 247, 4320 Aerotech Center Way New Item: (01/07)
Paso Robles, CA 93447 PAGE 1 OF 3
Telephone: [phone] Fax: [phone] Page Rev . Date: 03-16-11

TOYOTA CRAWLER TO DANA 300

TRANSFER CASE

KIT CONSISTS OF:

No. Qty Part No. Description

1. 1 51-5902 DUAL TRANSFER CASE ADAPTER PLATE

2. 1 51-9111 ADAPTER HOUSING

3. 1 52-5915 SHAFT

4. 1 51-5915A SHIFT RAIL BUSHING (Installed By AA)

5. 6 716065 10mm X 1.25" X 48mm SPECIAL STUD

6. 1 716511 O-RING

7. 1 716517 GASKET

8. 1 716323 NEEDLE BEARING FOR CLUSTER GEAR

9. 6 720012 10mm X 1.25" NUT

10. 4 723701 3/8"-16 HEX NUTS

11. 4 723704 3/8" LOCK WASHERS

12. 4 723711 3/8" -16 x 2" LG.

13. 2 300921 FILL & DRAIN PLUG

14. 1 911069 SPECIAL KEY STOCK

15. 1 TT001 TOYOTA TRUCK INSTRUCTION MANUAL

PREPARATION OF THE GEAR BOX

Disassemble the extra transfer case gear box. Detailed instructions can be obtained in our Toyota Truck manual or a
Toyota service manual. Locate the output shaft and remove it from the case. The reduction box requires the use of the
gear, bearing, thrust washer, steel ball and snap ring located on this shaft.

Remove the output shaft from the front case by removing the 4 bolts
with a 14mm socket. Remove the bearing retainer and snap ring.

Now that the roller bearing is removed, you will
see a spacer. Remove the spacer, low range
gear, and needle bearing. You will need to
retain these items to re-install on to the new
shaft.

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.

Remove the low range gear by removing the snap ring that
retains the roller bearing onto the rear shaft. Press the roller
bearing off of the shaft. Retain this bearing and snap ring to be
installed into the new adapter shaft.

ADVANCE ADAPTERS INC. P/N: 50-5915

P.O. Box 247, 4320 Aerotech Center Way New Item: (01/07)
Paso Robles, CA 93447 PAGE 2 OF 3
Telephone: [phone] Fax: [phone] Page Rev . Date: 05-04-12

TOYOTA CRAWLER TO DANA 300

TRANSFER CASE

The low gear and needle bearing must then be installed onto the new shaft supplied. The
thrust bushing and 1/4" ball will need to be placed on top of the output gear as illustrated.

The stock roller bearing will need to be installed into the adapter plate and is retained by
the 51-9111 when bolted to the plate.

We have also included a new caged needle bearing that needs to be installed into the
adapter housing for the cluster gear support.

Install the stock bearing into the adapter plate. Note the bearing is a press fit onto the shaft. To retain the bearing in the
adapter plate while pressing onto the shaft, we recommend, bolting the 51-9111 casting temporary to the adapter plate
which traps the bearing in place. This keeps the bearing in place while pressing the shaft on to it. Leave the new shaft
assembly standing upright on the work bench and install the bearing/plate on to the shaft assembly. This shaft assembly
is a light press fit. Once the shaft is installed through the bearing, remove the 51-9111 casting and then install the small
snap ring on the shaft. This snap ring will prevent the output shaft from traveling forward. Make sure the gear has the
proper end play .007-.010".

The shift fork or shift rod for the reduction box must be modified. A key stock has been provided to be welded to the
shifting component. This has to be done because this is the only shift rod retained in the crawler box.

With the proper end play determined, the
new shaft, gear, thrust bushings all in
position & assembled into the new adapter,
and the shifter modifications made, you can
now assemble this assembly on the reduc­tion gear box. Make sure that the new
bearing has been installed for the counter
shaft. Make sure that the shifter ring and
fork are in the proper location and the
pocket needle bearing is installed in the
output shaft.

Install the O-ring on the front of the 51-9111 casting. Install the 4 stud bolts and locktite them
into the crawler adapter plate. Then install the 51-9111 casting and secure it to the crawler
adapter.

The 51-9111 has two rotation options for the Dana 300 transfer case. Test fit the Dana 300 to
the adapter kit and check for shifter interference.

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.