I might have killed my Orion

[treerootCO]

The AA provided input gear has splines that are about 1 1/8" long.

OEM is 1 3/8" so the OEM has another 1/4" of splines to prevent the gear from walking back.

The 2nd pic is the width of the gear at about 1 11/16".

 

[treerootCO]

I just realized something!! I remember when I had everything on the bench I had a problem when I installed the input gear. If I tightened the retaining bolt, the tranny locked up tight. At the time, I thought I hit the bearing behind. I bet I was tightening the input gear to the inside of the transfer case!!

I guess it makes sense now...I added a spacer behind the large washer so that the bolt tightened to the output shaft instead of the t-case!!!

 

[peesalot]

O took a look at the splines on the a/a output shaft for the 420( old school ) and it is splined all the way and does need a spacer between the 2 bearings .

 

[treerootCO]

 

[treerootCO]

The bearings actually don't look bad. The metal is everywhere inside the case though. In the 2nd pic you can see what is left of the retainer that holds the seal in place. It machined it off, that is why it is sticking out of the case.

 

[peesalot]

pulling tcase tommorow , did yours have any visible indicators when viewed thru inspection cover , could you see gear wear on case prior to pulling tcase ?

was gear misaligned ? or did it look o.k. before pulling ?

 

[treerootCO]

You could tell that the gear had walked back when looking through the PTO cover. There is a pic on page 3. The gear should be tight against the washer.

 

[2badfjs]

there's no place like home

dude.....your turning into the tin man!

man i hope it all works out for you.

 

[treerootCO]

Parts are on the way from CruiserDan.

Took me almost a full day to disassemble and clean all the sparkly Orion parts.

If you get the case pulled pees, can you measure the thickness of the case where I destroyed mine? Can you take pics of the backside of your input gear and the inside of the case when mine was machined off?

Also, I think the reason nobody has had a problem running a plate style adapter without a spacer is because the OEM input gear has more splines to engage the output shaft. The case may be thicker as well. I didn't catch it early enough but I know the gear was touching the inside of the case when it was assembled.

 

[nuclearlemon]

Also, I think the reason nobody has had a problem running a plate style adapter without a spacer is because the OEM input gear has more splines to engage the output shaft. .

is it just me, or does that not make sense?

 

[Tigerstripe40]

Parts are on the way from CruiserDan.

Took me almost a full day to disassemble and clean all the sparkly Orion parts.

If you get the case pulled pees, can you measure the thickness of the case where I destroyed mine? Can you take pics of the backside of your input gear and the inside of the case when mine was machined off?

Also, I think the reason nobody has had a problem running a plate style adapter without a spacer is because the OEM input gear has more splines to engage the output shaft. The case may be thicker as well. I didn't catch it early enough but I know the gear was touching the inside of the case when it was assembled.

So, are you getting a new housing or are you going to be able to re-use what you have?

 

[Pin_Head]

is it just me, or does that not make sense?

I can translate that. The OEM 3sp input gear has longer splines which contact the end of the 465 output shaft spline so that the gear can't slide inward and wear the case.

 

[treerootCO]

Exactly

I am waiting on good Orion case measurement before I decide. I need to know the thickness of the part I machined off...at least how thick it was supposed to be.

 

[Romer]

Exactly

I am waiting on good Orion case measurement before I decide. I need to know the thickness of the part I machined off...at least how thick it was supposed to be.

Isn't Ian out measuring it for you

 

[treerootCO]

I can measure mine all I want. Maybe I can send Ian over to Hatfield's house to measure his case.

This is the difference in the gears:

 

[treerootCO]

more:

 

[peesalot]

working on it today , will post info asap. I would not worry bout the case , if it milled enough to be a prob you would have like 12 times the metal in there and it would have beeen noisy. put it together.

 

[treerootCO]

I am going to run it...

 

[treerootCO]

Update:

Got the parts from Dan today. Thank you Dan.

Detent Ball = 90360-10003
High-low shift sleeve = 36235-60011
Gasket kit = 04362-60030
Input seal = 90311-42014

The shift rail was sliding back and forth so I modified the retainer by welding it then grinding it back down. I also noticed the high/low shift collar was riding the gear in low but had slack in high so I shimmed the whole assembly futher toward the high gear with a very thin brass washer. Poser and I noticed that some of the retainers had a tab on one side. This one didn't have the tab. The washer would do about the same thing. The detent ball looked fine but it was replaced anyway. I ground the shift rail ever so slightly so the grooves are slightly deeper as well. you can see in the pics, my high/low sleeve was very warn (probably before assembly) that was my fault.

 

[treerootCO]

This picture shows where the shift sleeve was riding at one point in it's life. With the mods, the sleeve is now even. In low, it has the same slack as in high and in neutral, it is in the middle. Hopefully this solves the problem with the case shifting into neutral from high.