Advance Adapters AB1001 User Manual
ADV ANCE ADAPTERS, INC.
4320 Aerotech Center Way, Paso Robles, CA 93446
ASSEMBLY INSTRUCTION SHEET
Page 1 of 12 Rev. Date: 07-14-10 P/N AB1000 & AB1001
ATLAS 2 SPEED REBUILD KITS
P/N AB1000 32sp front output
Qty Part No. Description
1 300314 REAR OUTPUT BEARING
2 300355 CLUSTER THRUST WASHERS
2 300358 O-RING CLUSTER SHAFT
4 300370 BRAS SYNCRO RINGS
6 300372 SYNCRO DOGS
4 300373 SYNCRO DOR SPRINGSS
4 300383 SHIFT FORK PADS
2 300386 SET SCR EW F OR SHIFT FORK
2 300387 SEAL FOR SHIFT RAIL
1 300393 FRONT OUTPUT THRUST WASHER
2 300474 RUBBER SEAL YOKE WASHER
2 300476 YOKE NUTS
3 300490 O-RING FOR INPUT AND OUTPUTS
6 300491 TAILHOUSING BEARING SHIMS
1 300499 FRONT INPUT SEAL
1 300500 FRONT INPUT SEAL
1 300509 FRONT OUTPUT THRUST WASHER
1 300510 FRONT INPUT BEARING
1 300511 FRONT OUTPUT BEARING
1 300512 FRONT OUTPUT BEARING
2 300513 REAR OUTPUT BEARING
1 300514 REAR OUTPUT BEARING
1 300515 OUTPUT SHAFT POCKET BEARING
2 300516 CLUSTER GEAR BEARINGS
2 300517 HIGH GEAR BEARINGS
2 300518 LOW SPEED GEAR BEARINGS
1 300919 DRAIN PLUG SEAL WASHER
1 301400 PAN GASKET
1 716453 SNAP RING
1 716455 SNAP RING
6 300105S FRONT HOUSING BEARING SHIMS
P/N AB1001 26sp front output
Qty Part No. Description
1 300314 REAR OUTPUT BEARING
2 300355 CLUSTER THRUST WASHERS
2 300358 O-RING CLUSTER SHAFT
4 300370 BRAS SYNCRO RINGS
6 300372 SYNCRO DOGS
4 300373 SYNCRO DOR SPRINGSS
4 300383 SHIFT FORK PADS
2 300386 SET SCR EW F OR SHI FT F OR K
2 300387 SEAL FOR SHIFT RAIL
1 300474 RUBBER SEAL YOKE WASHER
1 300476 YOKE NUTS
1 300478 FRONT YOKE NUT
1 300480 FRONT YOKE SEAL WASHER
3 300490 O-RING FOR INPUT AND OUTPUTS
6 300491 TAILHOUSING BEARING SHIMS
1 300499 FRONT INPUT SEAL
1 300500 FRONT INPUT SEAL
1 300501 FRONT OUTPUT SEAL
2 300509 FRONT OUTPUT THRUST WASHER
1 300510 FRONT INPUT BEARING
2 300511 FRONT OUTPUT BEARING
2 300512 FRONT OUTPUT BEARING
1 300513 REAR OUTPUT BEARING
1 300514 REAR OUTPUT BEARING
1 300515 OUTPUT SHAFT POCKET BEARING
2 300516 CLUSTER GEAR BEARINGS
2 300517 HIGH GEAR BEARINGS
2 300518 LOW SPEED GEAR BEARINGS
1 300919 DRAIN PLUG SEAL WASHER
1 301400 PAN GASKET
1 716453 SNAP RING
1 716455 SNAP RING
6 300105S FRONT HOUSING BEARING SHIMS
NOTE: We have not included the 32 spline yoke seals in these kits due to the two yoke diameters. These seals
must be ordered separtly. The caged bearing that fit the in the rear output shaft is not included in this kit, it is a
low wear bearing and is very difficult to remove.
ADV ANCE ADAPTERS, INC.
4320 Aerotech Center Way, Paso Robles, CA 93446
ASSEMBLY INSTRUCTION SHEET
Page 2 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001
ATLAS 2 SPEED REBUILD KITS
Remove the transfer case from the vehicle.
Remove the drain plug and the drain oil.
Remove (14) torx head bolts and remove the inspection cover. Clean the surface of any debris.
Remove the cluster pin retaining the bolts.
Remove the cluster pin from the unit.
Remove the cluster gear.
Remove the two thrust washers from inside the case.
You should now have access to the shift fork set screws which need to be removed.
Remove the three bolts from the shifter control.
ADV ANCE ADAPTERS, INC.
4320 Aerotech Center Way, Paso Robles, CA 93446
ASSEMBLY INSTRUCTION SHEET
Page 3 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001
ATLAS 2 SPEED REBUILD KITS
Using a plastic dead blow hammer, use one hand to support the Atlas shift forks inside the case to prevent binding
on the shift rails and the other hand on the hammer, lightly tapping the shift rails from the front of the case. This
provides an easy way of pulling the shifter control from the Atlas case. Once the shift control is removed, clean
both the case and shifter control mating surfaces.
Remove the forks from the case. (Note: If you have Atlas case
#1929 or earlier and have not upgraded your shifter forks, this is an
ideal time to install new shift forks, P/N 301550).
Remove the 5 bolts from the front output shaft retainer and the 4 rear bearing cap bolts. Remove the front assembly
from the Atlas case. Note: The low range gear, bearing, spacer, and rear bearing will be left in the case.
Remove the front yoke nut and front retainer. Remove the bearing and spacer. The gear and needle bearing can
then be removed.
ADV ANCE ADAPTERS, INC.
4320 Aerotech Center Way, Paso Robles, CA 93446
ASSEMBLY INSTRUCTION SHEET
Page 4 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001
ATLAS 2 SPEED REBUILD KITS
Next, remove the shifter slider, the synchronizer springs, the synchronizer dogs and the brass rings.
Turn the case so that you are looking at the input ring. Remove the six bolts that hold it to the case. Use your dead
blow hammer to firmly hit the side of the transfer case while pulling on the input shaft. The tolerance on the input bore
should be a snug fit and may take a little while to work loose. We do not recommend using any type of prying mechanism
to get the input out; the aluminum is "softer" than a screwdriver or a pry bar and WILL get damaged and my cause
problems down the road. Once removed, there will be one synchro ring that will become free. Remove it from the
case, and place it in top of the synchro hub located on the input assembly you just removed.
Using your fingers, "pop" the synchro slider off the slider hub. When removed, three synchro dogs will become loose.
They may simply "fall" out or even "spring" out.
Remove the speedometer drive from the tail housing. If you have no speedometer drive but do have a freeze plug
blocking the hole, disregard and go to the next step.
Using an 1-1/8" socket, remove the output shaft nut and discard it. Depending on the mileage of your unit, the rear
yoke may be difficult to remove. You can use a puller if it is stubborn but most yokes can be removed with the use
of a dead blow hammer. When the nut and yoke are off, the output shaft will become "loose" in the case. DO NOT
ATTEMPT TO REMOVE THE OUTPUT SHAFT FROM THE CASE YET! There are a couple of parts which
are still holding it into the case.
Remove the five bolts holding the tail housing on the case. You may need to tap the tail housing to get it loose from
the case. Take the housing completely off the case and set it aside.
Use a set of snap ring pliers to remove the first snap ring from the shaft. Next, remove the blue plastic drive gear from
the shaft (may be a slightly snug fit). Remove the last snap ring and set those parts aside.
The last thing holding the shaft into place is the bearing on it. This bearing is another "light" press, and will require the
use of the dead blow hammer. Use one hand to hit the tip of the shaft with the hammer and the other hand to support
the large "pancake" gear inside the case. Visualize that you are driving the output shaft through the pancake gear and
out the front of the case. When the bearing becomes loose, slide it completely off of the shaft. Place it into the "old"
parts section. Pull the shaft fully from the front of the case. There is one more brass synchro slider, and one caged
needle bearing set that are now free. Remove the pancake gear from the case. There should not be any more parts
loose inside the case. At this point it is wise to clean and inspect your case and parts for any debris. Also inspect the
outside of the case and remove any silicon or sealing material.
Place the pancake gear on a flat surface with the synchro hub facing up. Take one of the brass synchro rings and place
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