Advance Adapters 50-8602 - Manual (Page 2)

DANA 18/20 TRANSFER C. TO ALL JEEP
TRANSMISSION 1980-02 (23-SPL OUTPUT)
ADVANCE ADAPTERS INC. P/N: 50-8602
P.O. Box 247, 4320 Aerotech Center Way Old Part No: 711086-23
Paso Robles, CA 93447 PAGE 2 OF 2
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 10-15-03
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.
This kit is designed for CJ5 and CJ7 Jeep vehicles equipped with the Dana 18 or Dana 20 transfer cases. This kit can also
be used with any Jeep transmission 1987 and newer having a 23 spline output shaft.
The adapter must be used with a Jeep T4 or T5 transmission that was previously coupled to a Dana 300 transfer case.
The front part of the transmission can be used with Jeep stock bellhousings or it can be adapted to either a Chevy or Ford
bellhousing by using an AA bellhousing kit. The overall assembled length of this new transmission and adapter kit will be
approximately 16-1/2" and may not fit vehicles with a short wheel base.
When used with an AX15, the AX15 output shaft may require shortening.
On installations using a 2 piece main shaft, make sure that the coupler and the output shaft do not bottom out. We have
found on occasion that a transmission output shaft may be slightly longer than we have allowed for; and when coupling
into our new spud shaft, we find a small amount of interference. The adapter housing and spud shaft must be assembled
to the back of the transmission without interference.
DO NOT FORCE THE NEW TAILHOUSING ONTO THE
TRANSMISSION. If assistance is needed, please free to call the number listed above.
1. Using the original Jeep bearing or a new 307 bearing, you must first install the spud shaft onto the new bearing.
2. Install the appropriate bearing retainer into the back of the adapter housing, Part No. 711177. The retainer will either
be a T90 or T86. If a T86 retainer is used, then be sure to install the external snap ring.
3. Install spud shaft with bearing onto the bearing retainer.
4. Install the oil seal with the open side towards the transmission.
5. Most stock Jeep tailhousing have a oil weep hole that leaks when the seal goes bad. Our spud shaft does not contact
this stock seal on all applications. We recommend plugging the weep hole / slot with silicone to prevent any oil leaking
from the transfer case.
6. Place the gasket over the transfer case face.
7. On large hole transfer cases, your can now install your output gear onto the new spud shaft and secure it with new
nylon lock nut. Maximum torque must be 75 ft./lbs.
8. On small hole transfer cases, you will need to install the gear through the inspection cover of the transfer case. On
installations that were previously equipped with a gear spacer, you will eliminate the spacer.
9. Bolt the adapter assembly to the transfer case using the original bolts from the transfer case side and the special socket
head cap screw from the adapter side.
10. With the adapter completely assembled to the transfer case, you can now install the adapter assembly to the main
transmission adapter. We recommend using RTV blue silicone between these two surfaces.