Advance Adapters Orion Transfer Cace User Manual

ADVANCE ADAPTERS INC. P/N: Orion

P.O. Box 247, 4320 Aerotech Center Way New Item: (06/04)
Paso Robles, CA 93447 PAGE 1 OF 15
Telephone: [phone] Fax: [phone] Page Rev . Date: 04-19-05

ORION TRANSFER CASE

Assembly & Disassembly

The Orion was created to replace stock transfer cases built between the years of 1963 and July of 1980. This case
replacement is the same external width, eliminating driveline modifications; however, the drain plug may be
approximately .500" lower than a stock case. The supplied 4:1 gear set replaces the existing gear set except for the
P.T.O. gear or P.T.O. spacer sleeve. It is required that you reuse your stock fasteners, front and rear housings,
retainers, shafts, clutch sleeves, and cover plates from your original transfer case. You are supplied a full rebuild kit
to replace all bearings, bearing cups, O-rings, seals, and gaskets. Shims for the rear output shaft retainer are also
supplied to set the bearing pre-load. Do not discard shims, washers, sleeves, and spacers from yokes and

shafts. Throughout the disassembly section, reference will be made to items that may be discarded. Attached you

will find 3 different illustrations referring to each component by our common terms.

site address to an interactive identification page @ www.advanceadapters.com/orion.html providing
actual photos of each component included in your Orion kit. In addition, this site address will include the
colored version of this instruction sheet.

We have also provided a web

Although this instruction sheet will initiate the steps to install the Orion, it is advised that you obtain a shop or repair
manual that covers your specific application.

Tools required:

Safety Glasses
Metric drive sockets
Metric wrenches
#10 hex bit
Foot Pound Torque Wrench (Torque Range of 10-125 ft./lbs.)
Drift Punch for both Hi and Low Shift Rail and 4 speed stake nut
Dead Blow Hammer
Pliers
Press (hand press)
Universal Puller for stock 3 and 4 speed transmissions
Flat Head Screw Driver

"A” kits (Bolt pack #400222) will also require:

5/8” socket
1-1/4” socket
3/8” hex bit

Note: When using the Orion transfer case

with a Marlin Toy Box, the Orion requires
modifications to the top of the case for the
Toy Box shifter rail. A special machined
case can be ordered from us with this
modification,

P/N O20001.

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: Orion

P.O. Box 247, 4320 Aerotech Center Way New Item: (06/04)
Paso Robles, CA 93447 PAGE 2 OF 15
Telephone: [phone] Fax: [phone] Page Rev . Date: 04-19-07

ORION TRANSFER CASE

POINTS OF CONCERN (PLEASE READ)

The success of an Orion Transfer case installation is dependant on the condition of the necessary components that are
to be reused from your stock case. Some of the most critical components that require your attention to detail are as
follows:

G26- HI/LOW CLUTCH SLEEVE - Inspect for excessive or worn splines. The splines should not be tapered throughout
the sleeve width. You will notice the “V” looking tapers or “boat tails” only at the last .070” to the contact sides
of the sleeve towards each gear. If you need a new sleeve, purchase Toyota Part # 36235-60010

S2- LOCK PLATE ASSEMBLY - This lock plate needs to be inspected to insure the proper fit into the notch of the
Hi/Low shift fork shaft. The machined recessed area provided in the case of Orion will establish the location of this plate.
Do not attempt to shim the location of the plate; this will only change the location of the clutch sleeve rendering neutral
to be out of position. Measure the thickness of the lock plate. A stock lock plate should measure on average .123”. If
you need to purchase a new lock plate, use Toyota # 36726-60010. These may be subject to low availability from a dealer.

S5 & S6- SHIFT FORK LOCK BALL AND COMPRESSION SPRING - We have provided a new ball, spring, and
brass set screw to be used for your installation. The ball provided measures 10mm and will tighten up the tolerance in
the shift fork bore. We have also provided a new spring which has a greater holding capacity than an older worn out
spring. The new brass set screw will take the guess work out of setting the tension on the spring and ball inside the new
shift fork. The brass set screw should be installed with a bit of Loctite to retain it, and the hex should be seated completely
to the shift fork. P/N O60050 - 10mm Ball, P/N O60051 - Shift Fork Spring, P/N O60052 - Set Screw

New Shift Rail P/N O60040 & O-RINGS O60041.

G22 & G29- THRUST WASHERS - The thrust washers are an important and critical area when installing the Orion
gears on your Toyota shaft. The first step is to inspect the transfer case output shaft for excessive wear and to make
sure the gears fits the shaft. If your shaft is worn excessively, the gear will be a loose fit or will be able to wobble. If
this is the case with your shaft, replace it. We do offer replacement shafts.

If the shaft is in good shape, then proceed. The end play of the gear on the shaft must be set. The new Orion gears
are the same width as a stock gear set. On the early Orions the stock thrust washers were retained and the end play
on the gears is what the stock unit had. Unfortunately, in some applications the end play ended up to be close to .030".
The factory could have been off or if at some time the output shaft was changed, it could have had
different than stock measurements. The shaft and gears should be set at .008"-.012" of end play.
We now include two new thrust washers to help set up the transfer case with the correct end play.
These thrust washer are stepped. One side has a recess of .015" - .017" and the other side of the
washer has a .008" - .010" recess. So by using one side or the other of the washer or using your
stock washers, you should be able to get close to the required tolerance. P/N O60080 (2 required)

If you should have any further questions please call us @ 1-800-350-2223.

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.

ADV ANCE ADAPTERS INC. P/N: Orion

P.O. Box 247, 4320 Aerotech Center Way New Item: (06/04)
Paso Robles, CA 93447 PAGE 3 OF 15
Telephone: [phone] Fax: [phone] Page Rev . Date: 04-18-05

ORION TRANSFER CASE

Assembly & Disassembly

Orion Instructions:

The following instructions cover the disassembly of your stock transfer case along with the assembly of the Orion
transfer case. Listed throughout these instructions, we refer to various item numbers. These item numbers represent
components on one of the three schematics shown at the end of these instructions. The item numbers listed represent
the following: "C" is the case schematic, "G" is the gear schematic, and "S" is the shifter schematic. These drawings
also have an index page that corresponds the common terminology of these components.

Drain gear lubricants from transmission and transfer case.
Remove the parking brake drum retaining nut.

On 1963 to 1973 10-spline T/C, or as we'll term 3 Speeds - Reference item #’s C9, C10, C11. Retain item C9
On 1974 to 1980 16-spline T/C, or as we'll term 4 Speeds - Reference item #’s C6, C7, C8. Retain items C6, C7
This should be done while still in the vehicle after
the front and rear drive shafts are removed. You
will be able to slide the brake drum off and then the

brake plate assembly. This will keep you from
having to remove the brake cable from the brake
plate. Once this is achieved, simply unscrew the
speedometer cable from the speedometer shaft
sleeve.

Stock Transmissions:

We strongly recommend that stock 3 and 4 speed transmission combinations be removed completely from the vehicle.
In order to remove the transfer case from your transmission, please refer to a manual that covers your application.

Advance Adapters (spud shaft style) transfer case adapter systems:

If you are removing a transfer case from a transmission that is using our conversion adapter, it is possible to only remove
the transfer case. It will be up to your own discretion to unbolt either the adapter housing from the transmission or the
transfer case from the adapter housing. In either instance, our conversion adapters require the transfer case to slide
rearwards only a few inches to disengage the transmission output shaft from our adapter spud 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.

ADVANCE ADAPTERS INC. P/N: Orion

PAGE 4 OF 15
Page Rev . Date: 04-18-05

Disassembly of Transfer Case:

Remove and retain output shaft rear bearing retainer C4.
You do not have to remove the speedometer assembly.

Remove and retain the speedometer drive gear and
spacer from the output shaft, Item #’s G32 & G33.

Remove and retain the front transfer
yoke. A wood block during removal
may help keep the flange of the yoke
from spinning.

When removing the yoke on 3 speed cases, retain washer C25; and
on 4 speed cases, retain both washer and shim C21 and C22.

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: Orion

PAGE 5 OF 15
Page Rev . Date: 04-18-05

Remove and retain the front driveshaft shift assembly from your transfer case:

Vacuum- Diaphragm cylinder and transfer front drive fork
Mechanical- Transfer front drive shift shaft guide assembly (pictured)

Remove and retain the transfer extension housing with
its internal parts, Items C28, G16, G17, G18, G20.

With a dead blow hammer, drive out
the front output shaft G18.

Remove and retain snap ring G16
from extension housing C28. Press
out ball bearing G17 and discard.

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.