Advance Adapters AB1001 - Manual (Page 7)

ADVANCE ADAPTERS, INC.
4320 Aerotech Center Way, Paso Robles, CA 93446
ASSEMBLY INSTRUCTION SHEET
Page 7 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001
ATLAS 2 SPEED REBUILD KITS
Next to go on is the roller tapered bearing (the larger of the two new bearings). Preferably, it needs to be pushed on
by hand. Please put adequate pressure on the output shaft so it does not slip out of the synchro dog grooves. If it fits
a bit tighter than what you can do by hand, you can take a drift or brass punch to tap it on. Please try to only tap on
the inner race, the outer cage can get damaged very easily. When the bearing is fully seated, rotate the shaft one more
time to check the dog alignment.
Locate the new output shim and slide it over the shaft. Put the shim on the shaft with the "heavy chamfer" side down.
This shim is simply a piece of steel that has been machined to a specific thickness. This thickness determines the
endplay of the shaft.
Grab the new rear housing and stretch the new square "o-ring" over it. We have included two new seals with your
upgrade kit. Select the correct one that fits your yoke, but do not press it into the casting yet. Locate the smaller tapered
roller bearing. Take this bearing and place it into the correct race (which is pressed into the casting). Make sure you
have placed it with the rollers towards the race. Carefully press the seal into the casting until it is flush. Slide this
assembly over the shaft and guide it until it centers into the case. When the housing has been placed up to the case,
rotate until the holes are lined up. Use silicon on the 5 new bolts, and torque them to 25 ft./lbs. Try and use a star
type pattern when you torque the bolts.
You should now have the tailhousing secure to the back of the transfer case. The output shaft will be loose still, so
be careful not to let the dogs become miss-aligned. You are ready for the yoke. Find the new plastic yoke spline washer
and place it over the threaded portion of the shaft. Take the yoke and hold it with the "u-joint" side away from you.
Place a small bead of silicon around the inside of the spline portion. Lubricate the seal with a small amount of oil and
start the yoke on shaft about 1/2 of an inch only. Start the new nut by had a few turns. Use the nut to suck the assembly
together. (Putting the yoke all the way on by hand will allow the spline washer to "pop" out of the front which gets
the silicon all over; and this forces you to start over).
It is very important to make sure that the entire output shaft
assembly does not become locked up at any time during the nut tightening. If the assembly does lock up, STOP! Verify
that the shim went on BEFORE the small roller bearing, and also that the brass synchro ring has not become miss-
aligned with the dogs.
The assembly will have a small amount of resistance when almost tight, which is normal; a full
lockup does require your attention. Remedy the situation before continuing to torque (or call for tech assistance). If
the assembly is still free to rotate, get the torque as close to 150 ft./lbs. as you can (final torque can be done when the
case is installed into the vehicle).
The front input assembly is held together by a couple snap rings. Remove the snap ring that hold the gear to the shaft,
the gear should be a snug fit to the shaft and may require a slight tap to remove. Once the gear is removed, the shaft
is pressed out the opposite side. This should also expose the snap ring that holds the roller bearing into the front housing.
Re-assemble using the new bearing and the proper seal for the input spline shaft of your Atlas.
Find your input assembly and place the brass synchro ring over the hub. As you did before, press firmly on it so it gets
"stuck" on the hub. Replace the old square o-ring seal and guide the assembly into the case. When it has been pushed
into the front of the case, you need to find the dog grooves just like before. Rotate the assembly until it pushes fully
in and seats into the grooves. Use the six new bolts and reuse the six flat washers to attach it to the case. Use a small
amount of Loctite 242 on the tip of the bolt, and a small bead of silicon about half way down the bolt (this seals the
head of the bolt and also secures it from backing out). Torque in a star pattern to 25 ft./lbs. Check again to make sure
that the input spins free of the output shaft. Locking up indicates the miss-alignment of the dog grooves.