I might have killed my Orion

[treerootCO]

on the inside

Been wheeling every week....still have a problem with her popping out of low on slight downhill grades. I removed the brass washer mentioned above and that helped. I am wheeling Mosquito Pass Mon or Tues and I refuse to look at the oil until the summer is over. I hate to tear the Cruiser apart when I can be enjoying the summer driving my truck.

 

[madoc1]

good luck jim

 

[peesalot]

you did use the supplied bolt with the clearanced shank didn't you ?

 

[andrewfarmer]

a little off subject, but which diff gears are you guys using that sook like that? I have had a few sets of "Yukon"s and they never showed any flakes. ( I also run syn if that matters)

You should read the instructions
Always run gears in with a non-synthetic - they need to wear to bed in properly.
Then put synthetic in...

 

[Poser]

Mike-


Have not heard anything, is this good?


Have you changed oil lately, how did it look?



Update please.



Thanks!

 

[treerootCO]

I refuse to check . My 40 was down for a long time so I took this summer to get out every chance I could. It still pops into neutral but not very often. I think a little more tweaking and she'll be fine. I can check the fluids for you here shortly...

 

[Poser]

Mike,

I am very interested in what your drain plug looks like, and how the oil looks, compared to the crap you drained out previous. I am glad that you found the source of all that metal, and have been able to get out and use your truck!

Have you talked with AA about 'stepped' thrust washers, to limit the movement of the gears on the main shaft? I am having some machined for the one I am building for Ed Long. Taking longer than I thought, but I am pretty certain that this should all but end the t-case shifting into neutral issue. Spent at least an hour and a half on the phone with Randy at AA. He is a very knowledgeable person on these cases. I guess Marlin has been doing this when building stock cases for years, and continued with the Orion builds.


The one in the Yellow truck popped out of high range a couple times in the Hills, but not low, and his is the only one that is doing it, of the ones that I have built. When I get done with Ed's, Tim's is going to be removed, torn down, and the stepped thrusts installed. When I get the thrusts back from the machine shop, I will try and post up pics.


Thanks Mike!


-Steve

 

[Josie'sLandCruiser]

Hi All:

Jeeze! I wonder how many sales AA has lost because of this SNAFU with the Orion!?!

Went 'wheeling with a buddy with an Orion in his FJ40 (mated to an H41) couple of weekends ago; he rigs-up a bungy cord to keep the t-case in low range while idling down steep grades! I think I'd be fairly pissed to have to rig-up a bungy cord to keep my new $1500 t-case in gear!!

Do you guys think substituting all new Toyota factory parts for the items re-used from your "old" t-case would solve the problem, or is there more to this issue (like, perhaps a design failure?)

Regards,

Alan
Seattle

 

[nuclearlemon]

it's the main reason i haven't bought one....damn...i loved driving mike's up the wall, but too many issues and is the looooooowwwwww range with headaches really worth it?

 

[Poser]

Alan-


I only use new shift collars and mainshafts that do not show any significant wear. When I ordered my initial eight cases, I also ordered main shafts, shift collars for all of them, along with thrust washers, fine spline front output shafts/couplers and detent balls and springs. I could not see the logic in using worn parts in something, but that is just me.


Good luck!


-Steve

 

[Poser]

Guess I do not see it that way Iggie....

 

[lone gunman]

i know a guy who own's a local 4x4 shop and he wont even sell them any more because of customer complaints. just my .02

 

[spotcruiser]

Steve,

By main shaft, are you referring to the transfer case output shaft?

Thanks.
Todd Bull.

I only use new shift collars and mainshafts that do not show any significant wear. When I ordered my initial eight cases, I also ordered main shafts, shift collars for all of them, along with thrust washers, fine spline front output shafts/couplers and detent balls and springs. I could not see the logic in using worn parts in something, but that is just me.
-Steve

 

[Poser]

Todd-


Yes.


The transfer case main shaft is the rear output shaft. The high speed and low speed output shaft gears are retained on this shaft by the two taper roller bearings on each end...




-Steve

 

[madoc1]

poser, the orion i built hasnt popped yet to my knowledge, but curious as what stepped washer you are referring to where does it go?


thx jim

 

[Poser]

This stepped thrust washer will go between the mainshaft bearings and the high and low speed gears on the mainshaft. The step is a relief cut into the trust washer, allowing it to sit closer to the gears. This is to limit the amount that the gears can move for and aft, and possibly be contacting the shift collar, and bumping the case into neutral.


I am hoping to have pictures of all this posted here in the next couple days, provided I get the thrust washers back today....


Hope that helps!


-Steve

 

[treerootCO]

If this does the trick, save one for me. I actually had a nightmare the other day that I was wheeling RedCone and the Orion came out of gear and I died. Strange thing is I don't dream too often and I can only think of a few nightmares. Woke up damn near screaming

 

[Poser]

Not 100% sure this will be a 'cookie cutter' fix...as in ' all thrust washers need a .012 step cut in them'.....or whatever given number...seems like .010 gets you close, but I really only want to do this once.


A customer built his own, and has dropped off the 465/Orion and wants me to install it...and has since called and wants me to tear his case down and install these...


Guess after I do a few there will be a number to get you close...but thrusts are not spendy really, so I was going to order a pile, and have them cut in different increments...



-Steve

 

[1Fine40]

I am hoping to have pictures of all this posted here in the next couple days, provided I get the thrust washers back today....
-Steve

Any luck with this yet Steve? Would love to know if it is worth doing....
Thanks!

 

[Nick the Carpenter]

Not 100% sure this will be a 'cookie cutter' fix...as in ' all thrust washers need a .012 step cut in them'.....or whatever given number...seems like .010 gets you close, but I really only want to do this once.


A customer built his own, and has dropped off the 465/Orion and wants me to install it...and has since called and wants me to tear his case down and install these...


Guess after I do a few there will be a number to get you close...but thrusts are not spendy really, so I was going to order a pile, and have them cut in different increments...



-Steve

gday steve just a note i have just finished building my case and i did a bearing conversion on the hi and lo gears. Had the gears bored to take a needle roll and put taper bearings in the idler so far so good.Just waiting on new brake drum and ready to go