O R I O N

Poser · 02-23-07, 04:57 PM

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

1Fine40 · 02-23-07, 05:12 PM

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!

peesalot · 02-23-07, 05:40 PM

#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.

calstyl2 · 02-23-07, 06:29 PM

#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

cruiserhead · 02-24-07, 07:02 AM

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.

treerootCO · 02-24-07, 07:05 AM

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.

meat · 02-24-07, 11:17 AM

#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.

green73 · 02-24-07, 06:31 PM

#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.

chattfj40 · 02-25-07, 11:01 AM

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.

wapitidon · 03-05-07, 09:44 AM

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.

greenfox · 03-05-07, 06:39 PM

#303 4:1 new cut gears shift fork,new coller, cant remember the rest?

coiled40gary · 03-06-07, 09:47 PM

#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

Wheelin4 · 03-08-07, 06:52 PM

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.

Degnol · 03-13-07, 03:04 PM

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

lemon · 03-14-07, 07:53 PM

#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.

peesalot · 03-15-07, 03:49 PM

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.

lemon · 03-15-07, 04:05 PM

Quote:

Originally Posted by peesalot

where'd ya get the billet cone ?
As far as I know Poser is hording the remaining ones

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.

bunnyhill · 03-26-07, 06:49 PM

#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

65swb45 · 03-26-07, 10:25 PM

#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.

Toyland4x4 · 03-27-07, 09:03 AM

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.

D'Animal · 04-01-07, 12:07 PM

# 318 with the 3:1 reduction

Dave Adam's at Extreme 4x4 in Fresno, CA did the build up and the install.

cpg · 04-15-07, 07:33 PM

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

Blucruz · 04-18-07, 10:20 PM

#370
Just picked it up last week from AA. Still in the box in the garage. 3:1 gears. Going behind a TH400.

sfrolich · 04-21-07, 01:06 PM

#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

atchonda · 04-26-07, 10:58 AM

#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.

1Fine40 · 04-27-07, 01:12 PM

[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!

cpg · 04-28-07, 12:40 AM

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!

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.

02-23-07, 06:29 PM	#4
calstyl2 Whodats Momma has crabs Join Date: Mar 2005 Location: Cherry Valley CA TLCA# 14149 Posts: 959 Blog Entries: 3	#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 I think I might have found an example of why people think you might be a nutjob of Rugster proportions.-Gumby to BrianOR You may get a better response if you post this in 80 tech. =Junk RE dinner plates It's way past time you shut the f&%k up and go away. Subtle and less direct suggestions seem to go over your head, so it looks like it needs to just be put out there and said.=Gumby

02-24-07, 07:05 AM	#6
treerootCO Where are my keys?! Join Date: Jun 2004 Location: Wheat Ridge CO TLCA# 14133 Posts: 2,479	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. __________________ aka Mike D.----->Bio Page "Its better to be thought a fool rather than to speak up and remove all doubt." - Lincoln pride is ego, the word I had lost was dignity. The quality or state of being worthy of esteem or respect. www.root45.com www.risingsun4x4club.org TLCA #14133 Last edited by treerootCO; 04-20-07 at 11:36 AM.

02-24-07, 11:17 AM	#7
meat IH8MUD Junior Join Date: Feb 2005 Location: western wa. TLCA# 14682 Posts: 94	#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. __________________ 2000 uzj100 '77 fj40 2f/h42/orion; OME 2 1/2 in lift/ 4wdb '64 fj45swb

02-24-07, 06:31 PM	#8
green73 What's broken now? Join Date: Sep 2002 Location: East Coast Virginia TLCA# 12222 Posts: 639	#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.

02-25-07, 11:01 AM	#9
chattfj40 IH8MUD Reader Join Date: May 2004 Location: Chattanooga, TN TLCA# 4920 Posts: 507	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. TLCA#: 4920 STLCA Rescue Tellico Committee (SFWDA) And yep...I am White Trash Last edited by Poser; 02-27-07 at 03:35 PM.

02-23-07, 04:57 PM	#1
Poser Oh...Durka Durka Durka. Join Date: Oct 2003 Location: in the shop TLCA# 1856 Posts: 13,949	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.

02-23-07, 05:12 PM	#2
1Fine40 IH8MUD Regular Join Date: Aug 2003 Location: Wild Idaho TLCA# 2581 Posts: 481	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. "There is a fine line between "hobby" and "mental illness." Last edited by 1Fine40; 02-23-07 at 05:12 PM. Reason: Forgot something....

02-23-07, 05:40 PM	#3
peesalot IH8MUD Lifer Join Date: Sep 2004 Location: in a house Posts: 1,453	#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. __________________ John on the hawgs

02-24-07, 07:02 AM	#5
cruiserhead GCLC President Join Date: Jul 2003 Location: North Jersey TLCA# 15185 Posts: 542	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. 1978 FJ40 under construction-soon to get a 3FE `93 Chevy 1500 Suburban family hauler, 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

03-05-07, 09:44 AM	#10
wapitidon IH8MUD Rookie Join Date: Feb 2006 Location: Nice CA TLCA# 2589 Posts: 44	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,26 years of stuff for me '87 60- ome,wifes dd for 18 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

03-05-07, 06:39 PM	#11
greenfox IH8MUD Addict Join Date: Aug 2005 Location: Stockton, CA TLCA# 13526 Posts: 632	#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

03-06-07, 09:47 PM	#12
coiled40gary IH8MUD Junior Join Date: Jun 2005 Posts: 117	#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

03-08-07, 06:52 PM	#13
Wheelin4 IH8MUD Rookie Join Date: May 2005 Location: Up 4 Posts: 49	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.

03-13-07, 03:04 PM	#14
Degnol Noaccount Webwheeler Join Date: Jan 2003 Location: Kansastitty TLCA# 14529 Posts: 6,139	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 __________________ There is nothing so depraved as a man in the depths of an ether binge '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

03-14-07, 07:53 PM	#15
lemon IH8MUD Rookie Join Date: Jun 2005 Location: An alternate reality TLCA# 1882 Posts: 63	#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.

03-15-07, 03:49 PM	#16
peesalot IH8MUD Lifer Join Date: Sep 2004 Location: in a house Posts: 1,453	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

03-26-07, 06:49 PM	#18
bunnyhill IH8MUD Rookie Join Date: Jun 2005 Posts: 34	#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....

03-26-07, 10:25 PM	#19
65swb45 elder statesman Join Date: Apr 2004 TLCA# 1086 Posts: 6,124	#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, 76HJ45,84FJ60, 76K5, 73Sub454, 89Sub7.4[gone], 97Sub5.7 TLCA delegate, Trail Crew-LAC TLCA, The White Trash of the Elwood Chapter my website: http://www.marksoffroad.net

03-27-07, 09:03 AM	#20
Toyland4x4 IH8MUD Rookie Join Date: May 2005 Location: So Cal Posts: 72	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 Adam C. Ventura CA TLCA# 6141 http://members.aol.com/toyland4x4

04-01-07, 12:07 PM	#21
D'Animal Beagles Rule! Join Date: Mar 2006 Location: Central California TLCA# 17104 Posts: 8,643	# 318 with the 3:1 reduction Dave Adam's at Extreme 4x4 in Fresno, CA did the build up and the install.

04-15-07, 07:33 PM	#22
cpg IH8MUD Addict Join Date: Dec 2004 Location: Livermore , Ca. TLCA# 2329 Posts: 629	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

04-18-07, 10:20 PM	#23
Blucruz IH8MUD Rookie Join Date: Apr 2007 Posts: 11	#370 Just picked it up last week from AA. Still in the box in the garage. 3:1 gears. Going behind a TH400.

04-21-07, 01:06 PM	#24
sfrolich IH8MUD Junior Join Date: Jan 2003 Location: Manhattan Beach, CA Posts: 143	#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, 3" lift, FJ60 rear springs

04-26-07, 10:58 AM	#25
atchonda IH8MUD Rookie Join Date: Feb 2005 Location: Sandy Oregon TLCA# 16733 Posts: 31	#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.

04-27-07, 01:12 PM	#26
1Fine40 IH8MUD Regular Join Date: Aug 2003 Location: Wild Idaho TLCA# 2581 Posts: 481	[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. "There is a fine line between "hobby" and "mental illness."