Advance Adapters 50-8603 - Manual

KIT CONSISTS OF:
No. Qty Part No. Description
ADVANCE ADAPTERS INC. P/N: 50-8603
P.O. Box 247, 4320 Aerotech Center Way New Item: (12/99)
Paso Robles, CA 93447 PAGE 1 OF 2
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 02-16-09
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.
1. 1 51-8603 ADAPTER CASTING
2. 1 716220 INDEX RETAINER
3. 1 716308 SEALED BEARING (716317)
4. 2 716517 GASKET
5. 6 723731 S.H.C.S. 3/8"-16 x 1"
6. 6 723711 STUD 3/8"-16
7. 6 723701 3/8"-16 NUT
8. 6 723704 3/8 LOCK WASHER
JEEP AX15 5 SPEED
TO JEEP DANA 300 TRANSFER CASE
INSTRUCTIONS:
This kit is designed to adapt the Jeep AX15 5 speed to the Jeep Dana 300 transfer case.
The AX15 was coupled to a NP231 transfer case from the factory. The NP231 has the front driveshaft on the driver's
side of the vehicle. When upgrading the axles, and if you get a front differential on the passenger side, you will need to
replace the stock transfer case. The best choice is the Dana 300 because of the 2.62 low gear ratio and all gear drive design.
The Dana 300 and NP231 both have the same input spline count, which is 23 spline. However, they have a different rotation.
This kit will allow you four rotation angles for the Dana 300, and proper spline engagement with little or no modifications.
A special front bearing retainer must be installed on the front of your Dana 300, replacing the stock retainer. In removing
the six Allen head bolts, there are two pry grooves located on the stock retainer. Use two pry bars into these slots to remove
this aluminum retainer. When the retainer is removed there is the drive gear, input shaft, and bearing on this retainer
assembly. By removing the snap ring on this assembly, these items will need to be taken apart. Once the items are
disassembled, you will need to set aside the stock aluminum retainer and the stock roller bearing. The new sealed roller
bearing has been provided due to the fact that the new aluminum retainer does not have a provision for a seal. Using these
new components, reinstall the Dana 300 input shaft assembly using the stock snap rings. Once assembly is assembled,
you will then need to reinstall this retainer assembly back into your Dana 300 transfer case.
The steel adapter plate must be rotated to line up the 6 counter sunk holes to the Dana 300. Use a gasket or RTV blue silicone
between these two components. Fasten the S.H.C.S. bolts with Loctite, securing the plate to the transfer case.
If you decide to use the lower rotation, you will need to grind a bit on the bottom of the Dana 300 shifter boss, due to
interference with the AX15 case. The upper rotation should not require modifications.
Once you decide on the rotation, install the six studs into the adapter ring (these studs are a tight fit into the ring). Use a
gasket or RTV blue silicone and fasten the transfer case to the transmission adapter plate.
Things to consider during the installation are floorboard clearances and transfer case shifter handle location & clearance.
Since we have rotated the Dana 300 up higher than the stock rotation, the shifter handle may need to be bent for proper
fit.
SPECIAL NOTE:
When replacing a New Process transfer
case in your vehicle with a Dana 300
transfer case, you must also change the
breather or vent cap on the end of the vent
hose. Failure to change this will cause the
transfer case oil to blow out the stock vent
cap.