O R I O N

Dedtruk · 12-29-08, 09:02 AM

Any update? Still staying in gear or ???

Quote:

Originally Posted by mudnyreye

I think mine is #121. It is an early one. It has worked perfect since installation. Soon after the bad pub came out, I took a trip to Tellico. I was fully loaded and coming down Trail 1 to the state line. It is a long downhill with whoops. Coasting pretty much, when I crossed the bridge at the bottom... no output on the running gear...Stuck! THE ORION CURSE!!! I crawled under the Cruiser and found that the shifter arm had popped off of the selector arm. Manually, I put it in 2HI, and was on my way. The entire weekend was spent underneath the Cruiser, switching it back into gear... I was really tick'd. I spent a tremendous amount of tim assembling my Orion. I spec'd everything, replaced anything less than tolerance and thought that I had a really tight T-case. Coming home, all the junk in my head about having to Yank it again, made for a bad ride. At the shop, I inspected everything and found the problem. R Front Motor Mount had separated causing the motor to Hop and hit the floor pan. Replaced the Mount and I have not had a problem since. I even went down upper 2.. No Problems. I love It!

spotcruiser · 12-29-08, 10:45 AM

No issues in the two years of wheeling since I built/installed it (#31, with the retro parts). I've been down a bunch of long, steep descents and it stayed in gear like it should. Of course, it takes some yankin' to get out of low four, but that's OK.

D'Animal · 12-31-08, 08:45 AM

Mine only pops out using the engine copmression for brakes.

Quote:

Originally Posted by spotcruiser

No issues in the two years of wheeling since I built/installed it (#31, with the retro parts). I've been down a bunch of long, steep descents and it stayed in gear like it should. Of course, it takes some yankin' to get out of low four, but that's OK.

If I ride the brakes, it does not pop out.

spotcruiser · 12-31-08, 08:09 PM

No problems with mine. I've intentionally stayed off the brakes, just to see how well it would hold, and it has not popped out. And we've done some ass-clenching steep descents the past couple of years. No issues yet.

Quote:

Originally Posted by D'Animal

Mine only pops out using the engine copmression for brakes. If I ride the brakes, it does not pop out.

orangefj45 · 01-01-09, 10:50 AM

Quote:

Originally Posted by D'Animal

Mine only pops out using the engine copmression for brakes.

If I ride the brakes, it does not pop out.

have you called AA about it? who built that case for you dan? i'll be more than happy to check it out for you if you wanna pull it and bring it to the shop. you've done me enough favors; freebie!

i'm working on another one right now as well; #393. it was installed by another shop and the rig has been back there multiple times for different issues from locking up to poping out of gear and leaking badly. the owner now wants nothing to do with the shop that installed/built the case originally. it now has a noticeable gear whine so i gotta pull it out next week and see what's going on. i'll keep you guys posted.

fwiw, i have built quite a few of these now and i've only had issues with one of them, but it's not poping out of gear; it's stuck in low gear. i will be seeing that case again in a month or so to see what happened. it's an early case and the customer lives out on the other end of the country. he installed the upgraded shift rail and detent himself after i built and installed the case in his rig. so we'll have to wait and see what happened there.

other than that, i have had virtually no issues with the orions. the first one i built resides in greenfoxs' fj40. it's been in there for over three years now with no leaks or other issues. it gets driven to the trail and on the street, done rubicon numerous times along with other trails i nthe sierras.

D'Animal · 01-01-09, 12:09 PM

I'm afraid if I pull it again, it will end up in the FJ40.5.

Quote:

Originally Posted by orangefj45

have you called AA about it? who built that case for you dan? i'll be more than happy to check it out for you if you wanna pull it and bring it to the shop. you've done me enough favors; freebie!

i'm working on another one right now as well; #393. it was installed by another shop and the rig has been back there multiple times for different issues from locking up to poping out of gear and leaking badly. the owner now wants nothing to do with the shop that installed/built the case originally. it now has a noticeable gear whine so i gotta pull it out next week and see what's going on. i'll keep you guys posted.

fwiw, i have built quite a few of these now and i've only had issues with one of them, but it's not poping out of gear; it's stuck in low gear. i will be seeing that case again in a month or so to see what happened. it's an early case and the customer lives out on the other end of the country. he installed the upgraded shift rail and detent himself after i built and installed the case in his rig. so we'll have to wait and see what happened there.

other than that, i have had virtually no issues with the orions. the first one i built resides in greenfoxs' fj40. it's been in there for over three years now with no leaks or other issues. it gets driven to the trail and on the street, done rubicon numerous times along with other trails i nthe sierras.

Blue77FJ40 · 01-05-09, 06:28 AM

orangefj45, where have you noticed the leaks from? Mine has a nasty leak from what I think is the nosecone flange. Hopefully I will be applying the popping into neutral fix (from both hi and low) this year and will address the leak at that time. TIA

orangefj45 · 01-05-09, 08:27 AM

that's a loaded question. the t-case i'm working on right now was leaking from just about everywhere, and i mean everywhere. i think a lot of time people forget to use the proper sealant both on the gaskets and on the threads of the bolts. i use loctite formula 518 on all the surfaces and bolt threads, just like i do when i rebuild a split case. some of the bolt holes are "live" oil passages; they extend into the case cavity and oil can and will creep along the threads. this is not the case for all bolt holes but there are a few on the orion and stock case. so make sure you seal the threads peoperly.

hth

georg @ valley hybrids

Blue77FJ40 · 01-05-09, 09:40 AM

George, I was very careful about the sealant being applied to the gaskets (I used hylomar) and on the live bolts (Perm 2B) you mentioned (mostly nosecone). In fact, I believe it was AA that mentioned to me to not add anything to the nosecone gasket, as it adds to the overall length and will affect the final torque adjustment on the output shaft.

Thanks, Dan

miker · 01-05-09, 02:37 PM

I've had good luck using Permatex High Tack Spray-A-Gasket Sealant on the transfercase gaskets. It does not add any thickness to the gasket so won't change the bearing preloads once they are set up right. Its very thin but very tacky and seems to keep oil from wicking through or past the gasket. Just don't apply it until you are sure you are ready for final assembly, until then, just install the gasket dry for setup.

One tricky part on the orion for oil leaks is the idler shaft o-rings. For me, I found that they were easy to cut or nick when installing the idler shaft. I think the newer Orions come with the shaft and gear already installed so this might not be a problem for most installs these days. I did mine several years ago when AA did not preinstall the shaft in the case.

Here's a pic of the Permatex. Easy to use because its a spray. Just be sure to clear the nozzle after each use otherwise it could clog. Nothing new, typical rattle can technique when you don't use the entire can at one time.

orangefj45 · 01-05-09, 09:53 PM

the idler has come pre-installed for quite a while now, in order to curtail the issues with leaky idelr shaft o-rings. they can be a little tricky, in the orion, stock case and split case.

i use the formula 518 on everything, gaskets and bolts. i make sure to get a nice even bead on both sides of the gaskets. most of the time i use my finger to smooth out the seatant as well.

Blue77FJ40 · 01-06-09, 08:31 AM

Thanks for the suggestions on the sealant. My Orion came with the shaft pre-installed, but I could easily see that o-ring on one side had two obvious breaks in it, and replaced it. Not super easy, as the o-ring kept wanting to pooch out as the shaft was going back in. After repositioning the idler shaft, I loaded both ends of it with Permatex 2B and haven't seen any leaks from there. Just the nosecone.

peesalot · 01-06-09, 02:16 PM

just a thought, is the nose cone true ? it may be warped.
My orion leaked from the rear of idler shaft for about a week. I was following Treeroots write up and changed my oil bout same time he posted the silver shaving pics and I had similar silver flakes that have been reasoned to come from gear break in. After the first oil change it never leaked a drop. It does pop outa high range sometimes but I have driven it enought o konw when it is gonna pop out and I deal. It never pops outa low.
FWIW I do think it needs to come out and get the update pieces to be right but I am a little lazy and it really is not all that bad.

gid1972 · 01-20-09, 09:08 PM

Orion HD #49, 4:1, and machined rear output to accept mechanical speedo gear. Working on install and hope to test it out soon.

orangefj45 · 01-29-09, 11:12 PM

Quote:

Originally Posted by gid1972

Orion HD #49, 4:1, and machined rear output to accept mechanical speedo gear. Working on install and hope to test it out soon.

post some pics shawn!

orangefj45 · 01-29-09, 11:14 PM

i'm still tinkering with #393. part of the rebuild will include updating the case to fine spline shafts, the later 4spd webbed nose-cone, a nose-cone saver and an updated breather in the top cover.
i'm still waiting on the new fine spline main haft but as soon as it gets here the case will be done. i'll post some pics then.

i also just placed an order for another orion for a customer. once it gets here and i start building it i will post back up with a little trick i use to help prevent o-rings getting cut or shaved during install.

D'Animal · 02-01-09, 06:58 AM

Orion 4:1 # 264

Not installed yet.

orangefj45 · 02-01-09, 12:00 PM

Quote:

Originally Posted by D'Animal

Orion 4:1 # 264

Not installed yet.

sweet! i guess you own two of those puppies now, huh?!

gid1972 · 02-26-09, 11:50 AM

Quote:

Originally Posted by orangefj45

post some pics shawn!

Working on that....haven't had much time to play this month...hoping to finish up the cross member this weekend, then i can test it out.....

orangefj45 · 04-01-09, 08:01 PM

Quote:

Originally Posted by gid1972

Working on that....haven't had much time to play this month...hoping to finish up the cross member this weekend, then i can test it out.....

come awn dude, pics!!!!!

orangefj45 · 04-01-09, 08:02 PM

case #2444 just finished, getting shipped east tomorrow.

orangefj45 · 04-01-09, 08:24 PM

can't help myself.

left to right:

1) NV4500 with case #264, being updated to an orion HD

2) new h55f with freshly rebuilt split case, installed into an fj40 today

3) case #2444 going to VT tomorrow

D'Animal · 04-01-09, 08:39 PM

SWEET!

mustardfj40 · 04-02-09, 04:41 PM

Quote:

Originally Posted by orangefj45

can't help myself.

left to right:

1) NV4500 with case #264, being updated to an orion HD

2) new h55f with freshly rebuilt split case, installed into an fj40 today

3) case #2444 going to VT tomorrow

Eye candies!!! Lots of money on that bench

D'Animal · 04-02-09, 10:58 PM

Quote:

Originally Posted by mustardfj40

Eye candies!!! Lots of money on that bench

I know how much is in the one on the left.

(I have bought complete, running FJ40's for less.)

mrqtipp · 04-03-09, 10:58 AM

Quote:

Originally Posted by D'Animal

I know how much is in the one on the left.

(I have bought complete, running FJ40's for less.)

I was wondering if that one on the left was yours Danno, I guess I have my answer.

Dont forget I still owe you some coin

Q

orangefj45 · 04-16-09, 09:49 PM

this will be delivered to you on saturday dan. orion #264 freshly converted to orion HD #52

D'Animal · 04-16-09, 10:03 PM

SWEET!

Blue77FJ40 · 04-17-09, 09:55 AM

Georg, how does the strength of the hd nosecone compare to the Warden's nosecone. Also, what's the advantange of going HD?

Thanks, Dan

Poser · 04-17-09, 10:10 AM

Quote:

Originally Posted by Blue77FJ40

Georg, how does the strength of the hd nosecone compare to the Warden's nosecone.

The front output housing on the Orion HD is not really an option for stock one-piece cases as it requires the use of the Advance Adapters 32 spline front and rear output shafts and uses a different arrangement to couple the front output shaft to the main shaft of the transfer case. These 32 spline output shafts are not compatible with OEM components of the stock Land Cruiser one-piece transfer case.

Quote:

Originally Posted by Blue77FJ40

Also, what's the advantange of going HD?

32 spline front and rear output shafts, which are the same size as those used in the Atlas II transfer case, compared to the significantly smaller OEM components.

No OEM parking brake provision, no OEM speedometer drive provision, requires different shift linkage.