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02-23-07, 04:57 PM
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#1 (permalink)
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Oh...Durka Durka Durka.
Join Date: Oct 2003
Location: in the shop
Posts: 15,935
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O R I O N
Do you have one?
If so, I would like to know your case number, ratio, if you have installed the stepped thrust washers, different shift rail, and back cut high-speed gear.
Post up what you have.
Thank you!
-Steve Cramer
__________________
Last edited by Poser; 03-26-07 at 09:26 PM.
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02-23-07, 05:12 PM
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#2 (permalink)
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250+ Club
Join Date: Aug 2003
Location: Wild Idaho
Posts: 546
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Case #2. Stepped thrust washers you sent me installed. Back cut Hi speed gear, latest shift rail,ball,spring and brass nut. Did not have the turned down long mounting bolt which was just above the idler gear, but have one in now. (yeah, the old one rubbed a little) Upon initial installation ran into problems with popping out of gear. Ran it a bit anyway. Took it all apart after a year to install new t-case output shaft, Hi/Lo selector ring, stepped washers etc. Seemed good for 8 months, then had massive bearing failure in the transmission (?) again took apart, repaired trans, reassembled case in haste when kid totaled DD work vehicle...(needed ride to work, so had to hurry) It's in there now, and seems quiet and happy. It is the 4:1 ratio gear set.
Cheers!
__________________
78' FJ40,SBC,35's,SR,PS,Lifted SUA,Orion#2, Aussie rr, RDB.
"No electrons were harmed for this post, just re-directed a tad"
Last edited by 1Fine40; 02-23-07 at 05:12 PM.
Reason: Forgot something....
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02-23-07, 05:40 PM
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#3 (permalink)
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Site Addict
Join Date: Sep 2004
Location: in a house
Posts: 1,722
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#100 , 4:1
used shift collar,rail from old t-case.
no back cut gear
runs well, pops outa high range when coasting downhill in 3 rd gear.
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John on the hawgs
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02-23-07, 06:29 PM
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#4 (permalink)
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Chat Whore
Join Date: Mar 2005
Location: Cherry Valley CA
Posts: 1,364
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#59
4:1
had pop outs in low range, extreme down hills only, not good for heart
had the gear cut and AA retrofit detent ball etc, shafts and parts from used 4 speed donor.
so far so good
love the case when its not trying to kill me
__________________
No cruisers, Im here for the Chicks and Beer
http://www.youtube.com/watch?v=nGVkHl-nBhE
Mud orientation video
xj was factory coil front and rear. the driveshafts are solid not hollow. the xj's weren't unibody. I know too much about heeps. Don't know what kind of lift it is though.
Lingo knows Jeeps
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02-24-07, 07:02 AM
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#5 (permalink)
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GCLC President
Join Date: Jul 2003
Location: North Jersey
Posts: 624
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Case #356,ratio 4.1,cut back gears,stepped thrust washers,new shift fork,shaft,ball,spring.Recieved this a week ago,have yet to install it.
__________________
1971-80 FJ40 Hey,I used what I had.Trail and plow truck.
`05 Trailblazer, wifes DD,`05 GMC 2500HD SLE Extra Cab 4x4 Cruiser Hauler,`95 Kawasaki Vulcan 1500
www.gclcny.com
Installer of Metal Tech products
Crum`s Custom Welding,LLC ccw1@optonline.net
Bumpers to roll cages,FJ40 skid plates-fits stock 3,4 speed & Orion trans and transfer case combos.1 year in development and Telico tested
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02-24-07, 07:05 AM
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#6 (permalink)
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Where are my keys?!
Join Date: Jun 2004
Location: Wheat Ridge CO
Posts: 2,737
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One of the early ones  I installed the stepped thrust washers, the new shift rail/ball/spring, and the back cut high-speed gear. Tolerances on the high low gears is .008 to .009. I didn't add the set screw to the shift rail.
Last edited by treerootCO; 04-20-07 at 11:36 AM.
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02-24-07, 11:17 AM
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#7 (permalink)
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Forum Regular
Join Date: Feb 2005
Location: western wa.
Posts: 147
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#338, set up by Gary Kardum (mudraks) back cut high speed gear, other than that he will have to answer since I either don't remember what he told me or he never said. Just got it last month.
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2000 uzj100 '77 fj40 2f/h42/orion; OME 2 1/2 in lift/ 4wdb '64 fj45swb
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02-24-07, 06:31 PM
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#8 (permalink)
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250+ Club
Join Date: Sep 2002
Location: Rosamond Ca.
Posts: 812
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#17 I just installed what they sent, by their instructions. Used all the necessarys from my old case. Never had any issues popping out of gear. 1st fluid change was as expected, just gear break in particles. The rear output seal is leaking a little now though. I can't remember any of my tollerances either, but they are within specs. Oh and the trans is an H41 too.
__________________
1973 FJ40: SOA, Locked, Caged, etc........... NEVER DONE!
1991 FJ80: Stock.... for a while. (now in my parents posession)
1996 FZJ80: Lives in the garage until I replace the head Gasket
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02-25-07, 11:01 AM
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#9 (permalink)
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IH8MUD Reader
Join Date: May 2004
Location: Chattanooga, TN
Posts: 689
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Case # 339
4:1
New main shaft and range shift collar
Had new high speed gear that was not back-cut, but cast that way.
Could not install the stepped thrust washers provided in the kit as even when using the thinnest step, the clearence was too tight.
Orion kit came with a new shift rail that had o-ring grooves on both ends, and was machined for the use of the set screw locking system, but the case was not machined for it.
Installed behind an H41
Assembly of this is detailed out here.
__________________
Please donate to the Rescue Tellico Fund and help save the Tellico OHV area
--Todd
Chattanooga, TN
1980 FJ40, H41/0rion, SOA, 38.5 TSL/SX, LF Beadlocks, Longs, Sag pwr steer w/ ram assist.
1994 FZJ80 w/ 6.5 Turbo Diesel, 6" Slee, Metaltech bumper, Kaymar R bumper.
TLCA#: 4920
STLCA Vice President
Rescue Tellico Committee ( SFWDA)
And yep...I am White Trash
David: is drinking a Blue Coconut Bacardi slushee! Ardenne is too! --Fireman on FB 2/7/09
Last edited by Poser; 02-27-07 at 03:35 PM.
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03-05-07, 09:44 AM
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#10 (permalink)
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Forum Regular
Join Date: Feb 2006
Location: Nice CA
Posts: 133
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case #139 installed on a 75 fj40
4:1
installed with directions included, used all parts from old case called for. no new gears or washers.
Installed in Dec. 04 and had popping out issues in 4H on 3 or 4 different occations first few hundred miles of build. Since then, 2 years-10,000 miles, 2 rubicons, no popping out.
__________________
Don Gatton TLCA #2589
Nice, CA
'81 40-bought new,been beating it ever since
'87 60- ome/stock,wifes dd for 20 years
'75 40-HFS 4" su,aussie rear,arb front,'81 discs,saginaw ps,fj60 ignition,4.56's runnin' 35's,headers thru a loud flowmaster and an ORION to make it easy for the kids to wheel
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03-05-07, 06:39 PM
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#11 (permalink)
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250+ Club
Join Date: Aug 2005
Location: Stockton, CA
Posts: 703
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#303 4:1 new cut gears shift fork,new coller, cant remember the rest?
__________________
73 FJ40 Green - Original
74 FJ40 Red - (BMFCAGE) SOA 36X17IROKS weldedrear ARBfront and what ever els you can think of
97 FZJ80 Green (the wife's) - locked
67 fj45lwb in the works
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03-06-07, 09:47 PM
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#12 (permalink)
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Forum Regular
Join Date: Jun 2005
Posts: 119
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#092
4:1
Bought mine through Gary Kardum, assembled it very carefully, called Gary while I was assembling to make sure I had the tensions right. Used the parts Gary did not provide out of my original t-case. Learned about the issues and modified parts quite a bit after I had installed it, so I did not know any better. Gary may have provided the parts you are referring to, I would not have noticed at the time.
I've had no problems yet, never popped out of gear, have not wheeled it hard yet, but has been my daily driver, 50 mile round trip though Columbia River Gorge and back into the Washougal River canyon. Not the usual in-town commute.
gary
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03-08-07, 06:52 PM
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#13 (permalink)
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Forum Regular
Join Date: May 2005
Location: Up 4
Posts: 48
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Case #355
4:1
My case was built by a local shop with all of the "new" components (thrust washers, shift rail, etc.) The only piece that wasnt used was the brass set screw for the shift fork. We used the stock piece as the large head of the brass screw wasn't clearing the housing cover.
Haven't had a chance to wheel it yet but will report back any problems.
BTW, mine is behind a SM465.
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03-13-07, 03:04 PM
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#14 (permalink)
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Forum Lifer
Join Date: Jan 2003
Location: Kansastitty
Posts: 7,309
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Orion # 151
4:1
New main shaft and range shift collar
Stepped thrust washers and back cut high-speed gear along with shift rail and detent ball
Installed behind H42
Poser-Built
And no problems except the driver
__________________
My Anger-Management Class really pisses me off
'66FJ40, Fresh 2F, H42/Orion(By Poser... LCR4WD), ARB Front/rear(By Poser... LCR4WD), MetalTech Cage installed by Poser, Screw-ups fixed(by Poser) 4WDB Corvette Master, Mini Truck PS, 3.5" Lift, Warn 8274, 33s on stockers, WhiteKnuckle sliders
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03-14-07, 07:53 PM
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#15 (permalink)
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Forum Regular
Join Date: Jun 2005
Location: An alternate reality
Posts: 63
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#150
4:1
New main shaft and range shift collar.
Upgraded front output to fine spline and installed a Warden billet nose cone.
Has stock shift rail, ball, spring and set screw.
Will pop out of high range occasionally on road while decelerating, low range was fine.
Does not have back cut high speed gear.
Installed behind an SM420.
__________________
"Load up on guns, bring your friends"
10/73 FJ-40
10/95 FZJ-80
Last edited by lemon; 03-14-07 at 08:00 PM.
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03-15-07, 03:49 PM
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#16 (permalink)
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Site Addict
Join Date: Sep 2004
Location: in a house
Posts: 1,722
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where'd ya get the billet cone ?
As far as I know Poser is hording the remaining ones , maybe Georg has one.
I bet there are a few out there, anyone wanna sell one ?
Note: #100 is popping outa gear after she gets heated up , only hi range tho. And only on 3rd gear decellaration.
__________________
John on the hawgs
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03-15-07, 04:05 PM
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#17 (permalink)
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Forum Regular
Join Date: Jun 2005
Location: An alternate reality
Posts: 63
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Quote:
Originally Posted by peesalot
where'd ya get the billet cone ?
As far as I know Poser is hording the remaining ones
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Steve purchased three of them from Danny Warden. I have one on my case, Bunnyhill has one on his, and the other one is on the case that he removed from his Red truck when he switched to the Atlas.
__________________
"Load up on guns, bring your friends"
10/73 FJ-40
10/95 FZJ-80
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03-26-07, 06:49 PM
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#18 (permalink)
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Forum Regular
Join Date: Jun 2005
Posts: 34
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#013
4:1
New main shaft and range shift collar.
Upgraded front output to fine spline and installed a Wardens billet nose cone
Has stock shift rail, ball, spring and set screw.
Does not have a back cut high-speed gear or stepped thrust washers.
Does not pop out of gear.
Installed behind a 465 and Marlin 2.28 Toybox
__________________
All liquored up and operatin’ heavy equipment....
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03-26-07, 10:25 PM
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#19 (permalink)
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elder statesman
Join Date: Apr 2004
Location: so cal, going 45
Posts: 8,206
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#262 installed in Ruftoys in March '06. Backcut hi speed gear, inboarded detents on shift rail, HUGE brass plug on shift fork [clearance issue with top cover] IIRC, I used stepped thrust washers provided by Poser.  Never popped out of gear yet. Then again, it won't shift from inside the truck either!
#350 assembled last month. All the same details as #262 except that shift rail now has a set screw [pic posted to Poser's thread] and like chattfj40, could not install the stepped thrust washer on one side. Yet to be installed.
__________________
A carbureted man in a fuel injected world.
65SWB45, 64LWB45, 68FJ40,72V840, 76HJ45[gone],84FJ60[gone], 76K5, 73Sub454, 97Sub5.7, 2002 Trailblazer
TLCA delegate, Trail Crew-LAC TLCA, The White Trash of the Elwood Chapter
my website:
http://www.marksoffroad.net
IT'S FASTER if you CALL ME!
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03-27-07, 09:03 AM
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#20 (permalink)
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Forum Regular
Join Date: May 2005
Location: So Cal
Posts: 73
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Case #51 4to1 haven't installed any of the repair parts. Went out of gear one time on a l o n g coast downhill on the freeway. Daily driver no problems.
__________________
1970 FJ40 350 NV4500 Orion Elocker front SO SR (for sale!)
2007 FJ Cruiser
Adam C. Ventura CA TLCA# 6141
http://www.toyland4x4.com
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04-01-07, 12:07 PM
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#21 (permalink)
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Beagles Rule!
Join Date: Mar 2006
Location: Central California
Posts: 15,841
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# 318 with the 3:1 reduction
Dave Adam's at Extreme 4x4 in Fresno, CA did the build up and the install.
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04-15-07, 07:33 PM
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#22 (permalink)
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250+ Club
Join Date: Dec 2004
Location: Livermore , Ca.
Posts: 666
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not sure what case number but did replace 2 thrusht washers with stepped ones for .004" clearance. does not pop out of gear any more
__________________
1996 FZJ 80, 1973 FJ 40
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04-18-07, 10:20 PM
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#23 (permalink)
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Forum Regular
Join Date: Apr 2007
Posts: 11
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#370
Just picked it up last week from AA. Still in the box in the garage. 3:1 gears. Going behind a TH400.
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04-21-07, 01:06 PM
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#24 (permalink)
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Forum Regular
Join Date: Jan 2003
Location: San Jose, CA
Posts: 187
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#302 with 4:1 built by Mudrak. Haven't tried low gear because my single shifter won't engage low, only high 2 and 4 wheel drive :-(
Scott
__________________
Nasty Looking 1971 FJ40, Chevy 350, Orion, NV4500 5-Speed,
Chevy (Saginaw) Power Steering, Tilt steering,
4 Wheel Power Assist Disk Brakes,
4" lift, Alcan custom springs
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04-26-07, 10:58 AM
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#25 (permalink)
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Forum Regular
Join Date: Feb 2005
Location: Sandy Oregon
Posts: 36
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#364 4:1 New main shaft, & range shift collar. Kit came with stepped thrust washers, high speed gear cast for shift collar clearance, new range shift shaft, with brass cap, & setscrew. Could not use stepped thrust washers, too tight. Not installed yet, hopefully this weekend. What do you guys think is the main updated part that cured the popping out of gear issue, after assembling this, it seems to me that the backcut gear is the piece that made the most difference.
__________________
Thanks, Warren
Too many toys & not enough time to play! 
In memory of Gary Johnson ONETON72GMC. RIP Gary, watch over us while we are in the woods!
76 FJ40 SOA, SR, Saginaw PS, 350, H42, Orion 4:1, rear detroit, front ARB, rear discs, Metal Tech family cage, OBA.
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04-27-07, 01:12 PM
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#26 (permalink)
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250+ Club
Join Date: Aug 2003
Location: Wild Idaho
Posts: 546
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[QUOTE=What do you guys think is the main updated part that cured the popping out of gear issue, after assembling this, it seems to me that the backcut gear is the piece that made the most difference.[/QUOTE]
From seeing the case assembled before the back cut gear and now after it, I have to think that played a major role in solving the problem. The shift shaft and good or new mainshaft shift ring don't hurt either. I'm a bit skeptical on the stepped thrust washers, but puttin' them all together, the case I have is sweet indeed
Cheers!
__________________
78' FJ40,SBC,35's,SR,PS,Lifted SUA,Orion#2, Aussie rr, RDB.
"No electrons were harmed for this post, just re-directed a tad"
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04-28-07, 12:40 AM
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#27 (permalink)
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250+ Club
Join Date: Dec 2004
Location: Livermore , Ca.
Posts: 666
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Quote:
Originally Posted by 1Fine40
From seeing the case assembled before the back cut gear and now after it, I have to think that played a major role in solving the problem. The shift shaft and good or new mainshaft shift ring don't hurt either. I'm a bit skeptical on the stepped thrust washers, but puttin' them all together, the case I have is sweet indeed
Cheers!
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On the case I have it was the thrust washer clearance. I was coming out of gear high and low range 2 and 4 wheel.
__________________
1996 FZJ 80, 1973 FJ 40
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05-04-07, 02:19 PM
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#28 (permalink)
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Forum Regular
Join Date: Oct 2003
Posts: 110
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I have one of the early one's also and have not installed it yet. It is going in soon though, what do I need to get to keep it from popping out of gear, and where do I get this stuff from?? Haven't been on here in awhile...
Thanks,
Fax
Called AA and I am sending their gear back to get fixed along with the other parts before it goes in. Thanks, All!
__________________
Fax
'80 FJ40 4" lift, 35's 2F.
'95 FZJ80 stock height, locked, 285's
Last edited by fj40fax; 05-04-07 at 03:00 PM.
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05-04-07, 02:30 PM
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#29 (permalink)
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... Alive
Join Date: Jan 2005
Location: The Greatland
Posts: 4,211
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Late coming in here...
I have #38. Assembled normally with perfect condition used parts. I had to add a .120 shim to the PTO port to get the right spacing of the PTO drive gears.
No problems, no popping out of gear.
Three seasons of hard use off road and long highway runs to the trail head. Currently behind a 2F/H42, putting a 350/SM465/203 in front of it at the moment.
Mark...
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05-05-07, 04:56 PM
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#30 (permalink)
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Forum Lifer
Join Date: Mar 2003
Location: on thin ice
Posts: 7,199
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i just built serial # 357 for a customer with the 4:1 gears. had a hell of a time setting up the correct preload on the output bearing. i've never had that problem before. turns out that the stepped washers for the output shafts were cut too much so the washer ended up bottoming out against the gear causing it to lock up with the shaft. i ended up running the stock washers and got the proper amount of freeplay between the gears and shafts that way. setting the output preload was a sinch after that.
hth
georg
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