Need Orion Technical Help Please

['74 UA FJ]

I've had the popping out of low range problem for a couple of years now. I just pulled my case out and I have some pics. The only thing that I can see that might be an issue is that the shift rail could be moved over toward the low side about an eighth of an inch to give a little more low range engagement. I will have to mill out the hole for the allen screw that holds the shift rail in place, and shim the clip that bolts to the outside of the case. No big deal to do. Does this seem like it would help?

I don't see any wear on the low gear except for a little bit of wear on the dog teeth. The wear is even on the high side, but on the low side, two teeth show contact, then two teeth don't, then two show contact, etc.

Take a look at the pics and tell me if I've missed anything. Any help is much appreciated!

On the first picture, this is how it looks in low range. In high range, the shift fork contacts the side of the case. I am thinking of moving the rail to the left until the fork contacts the left side of the case.

 

['74 UA FJ]

More pics:

 

['74 UA FJ]

And just because:

These are just pics of some work I'm doing. Spring over, cut and turn, new driveshafts, 30 longs, etc.

 

['74 UA FJ]

Well, I think I may have found the problem. The low speed gear has some play in it. Evidently, it worked itself loose after I ran it for a few months. This makes sense because I didn't have to the popping out problem at the very start, and then it got progressively worse. It may just need another shim in there and it will be good.

 

[TLC76]

Not related to ythe topic, but what fender flares are those? They look like they might work on my 7" lengthened wheelbase.

 

['74 UA FJ]

TJ...

 

[handcannon]

The last pic of you standing beside your great looking 40 provides me some good questions if you don't mind me asking them. First, are the tires 35s? Second, with you standing beside your 40 would provide me with a great proportioning aid if I new your height if that is not too personal. Next, what is the distance between the top outside edge of your front tire and the lower horizontal outside edge of the fender directly above the tire?

Don

 

['74 UA FJ]

They are 35x15.50 SXs, and I am 6' tall. I don't have the measurement for you, I have it torn back apart at the moment to sandblast and paint the axles. The rear springs are 60 series rear springs and the front springs are 55 series front springs. Wheelbase is about 4"-5" longer than stock.

 

[handcannon]

Thanks for the info.

The way your 40 is set up is what I have been wondering about for mine. I already have 55 rear springs installed front and rear SUA and just put on some used 315x75R/16 tires (supposedly equivalent to 35s). Your rear springs look almost identical to how the shackles and springs set on mine. I want more tire clearance but going SOA would add 7" according to my measuring. This concerns me because after last year I am dealing with a physical handicap that I think would make it difficult for me to get in and out if my 40 were that tall. BTW I'm also 6' and similar body build. I need to think outside the box to gain wheel clearance without making it difficult for me to drive it. BTW I like how yours looks and sets.

Don

 

['74 UA FJ]

Well, I think I may have found the problem. The low speed gear has some play in it. Evidently, it worked itself loose after I ran it for a few months. This makes sense because I didn't have to the popping out problem at the very start, and then it got progressively worse. It may just need another shim in there and it will be good.

Scratch this post. I measured clearances and I have .009" between the thrust washer and the low speed gear, and the same on the high speed gear. This is exactly how it was when I installed the case a couple of years ago. I'm at the point now where I am positive that the popping out of gear problem is due to an inherent design flaw, and the only way to remedy it is super strong spring detents or some other way to keep pressure on the shift collar, holding it in gear.

I remember when I first installed the case, I didn't pop out of low, or it took a super steep hill to do it. At that time, It was incredibly hard to shift from low to high because of the detent spring/ball, whatever. As the case got easier to shift, it started popping out of gear more readily to the point where I have to put it in 4th gear and ride the brakes going down even slightly steep hills.

Poser, orange45, mark, any of you guys have any suggestions while I have this thing apart?

 

['74 UA FJ]

ttt...

 

['74 UA FJ]

Bueller? Bueller? Anyone? Bueller?

 

[BC40]

Search - tons of good info from a couple years back on the solutions to popping out of gear. Stepped shims, back cut gear faces for clearance, etc. All parts that should be available from AA.

 

[65swb45]

Reassemble and take more measurements.

1. How much freeplay is there between the hi-lo fork and the groove in the hi-lo sleeve?

2. With the fork centered in the detent, how much room is there between the hi-lo sleeve and the backcut face of the lo speed gear when in lo range?

3. Same question for hi?

These are the clearances I will be examining when I take my Orion apart.

Best

Mark A.

 

['74 UA FJ]

Reassemble and take more measurements.

1. How much freeplay is there between the hi-lo fork and the groove in the hi-lo sleeve?

2. With the fork centered in the detent, how much room is there between the hi-lo sleeve and the backcut face of the lo speed gear when in lo range?

3. Same question for hi?

These are the clearances I will be examining when I take my Orion apart.

Best

Mark A.

Going on memory:

1: Not much, I'll have to get the calipers out. All of these pieces were brand new when I assembled my case.
2: 1/8"
3: about the same as low.


There's not much you can do here, unless your shift fork or collar is really worn. These are not.

 

['74 UA FJ]

Search - tons of good info from a couple years back on the solutions to popping out of gear. Stepped shims, back cut gear faces for clearance, etc. All parts that should be available from AA.

Have you even assembled an orion?