Advance Adapters Orion Transfer Cace - Manual (Page 2)

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: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 04-19-07
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.
ORION TRANSFER CASE
POINTS OF CONCERN (PLEASE READ)