Advance Adapters Orion Transfer Cace - Manual (Page 9)

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.
With idler gear and thrust washers in position, apply assembly lube to idler gear shaft G13.
Locate the groove cut into the idler shaft for the lock plate. Lightly lubricate and install the O-ring on this end
only. Install the opposite end of the idler shaft , into the rear side of the transfer case. Using a dead blow hammer,
lightly drive the shaft into the idler gear from the rear of the case.
We advise that extreme care should be taken
during this installation to prevent any risk of damage to the O-rings. We have included two additional O-rings
in the event that damage should occur. Drive the shaft beyond flush so that the idler gear shaft protrudes just far enough
to expose the O-ring groove on the front of the transfer case. Lightly lubricate and install the O-ring on the idler shaft
on the front side of the case. Lightly drive the shaft rearwards to its final position and install the lock plate and bolt G15.
Caution:
If this shaft is driven too far forward the rear O-ring will become exposed to an oil grove in the inner case. This would
cause the O-ring to bulge into this oil grove. When tapping the idler shaft back into its final position it would then cut the O-
ring causing the Orion to leak.
ADVANCE ADAPTERS INC. P/N: Orion
PAGE 9 OF 15
Page Rev. Date:
12-29-05
Apply assembly lube and slide high speed gear G24 onto output shaft G25. Next, slide your stock thrust washer or one
of the new stepped thrust washer provided (G22) onto shaft. (NOTE: Two new thrust washers have been provided.
You will find that each side of the new thrust washers have a recess/step. One side of the washer is .008"-.010" and
the other is .015"-.017". These steps will ride against the shoulder of the shaft and provides a tighter tolerance or end
play on the gear. The ideal end play on the gear to the thrust washer should be .008" to .012". A feeler gage should
be used to obtain the correct end play.) Drive on the front tapered roller bearing G21 using a dead blow hammer and
P/N 400250 tubular bearing tool. Be sure to drive against the inner race only.