Build Lynchburg Lemonade, matzell's STW

[matzell]

So all the missing parts showed up for the Orion. Game on! Got this put together this afternoon. Hooked up to a spare H41 tranny. I added a fine spline front output shaft and the nose cone saver for good measure. Hope to get it swapped tomorrow.

 

[RWBeringer4x4]

Advance Adapters is making me nervous lately - you were missing parts too?

 

[matzell]

Advance Adapters is making me nervous lately - you were missing parts too?

The gear sets, idler and low gears. Only gear that showed up was the input gear. Funny they charge extra for the 16 spline gear for the 4spd case but do not send the 3spd gear?????

Everything went together well and is tight. It shifts from high to low stiff even without the detent ball in. I used assembly lube in the thick grease version. I hope it loosens up once all the gear lube works in. All the backlash came within specs. I had a Haynes manual to show me specs and exploded views. Funny they do not include instructions on how to assemble it. I do not know how much time I will have to get on it today, some things came up.

 

[archie73]

The gear sets, idler and low gears. Only gear that showed up was the input gear. Funny they charge extra for the 16 spline gear for the 4spd case but do not send the 3spd gear?????

Everything went together well and is tight. It shifts from high to low stiff even without the detent ball in. I used assembly lube in the thick grease version. I hope it loosens up once all the gear lube works in. All the backlash came within specs. I had a Haynes manual to show me specs and exploded views. Funny they do not include instructions on how to assemble it. I do not know how much time I will have to get on it today, some things came up.

Funny, mine came complete with all parts and instructions. But as you two have read I’m having some issues... still haven’t fount time to tear it back apart. On plus side, I’ve driven over the pass a few times and it’s staying in gear. Probably won’t stay that way.

 

[matzell]

I pulled out the other H41 combo to make room for the new H41-Orion combo. I am finally "ok" with the shifting of the Orion from high to low and back to high after a little filing on the shift fork. Once in, now I need to adjust the shift lever so it does not hit the trans cover and allow it to go back to high range while at the same time not it the trans in low range. I may look into an aftermarket shifter???

 

[RWBeringer4x4]

So what created the issues with shift throw? Looks like the shifter is in the same place and the top cover is cannibalized from the donor case - but I hear about shifter conflicts all the time. Is the throw somehow longer than stock?

 

[matzell]

So what created the issues with shift throw? Looks like the shifter is in the same place and the top cover is cannibalized from the donor case - but I hear about shifter conflicts all the time. Is the throw somehow longer than stock?

I am not sure?? It should not be any longer than stock but does not seem the same. I had both side by side to compare. I may try to heat and bend the shifter above the shifter pivot point to allow it to clear the tunnel. I will post back later today after I play around with it some. I have looked at the shift lever and compared it to another one and they are the same size and shape.

 

[RWBeringer4x4]

This won’t be an issue for me most likely if/when I go this route - mine already has a big dog leg in it for my V8 conversion.

 

[matzell]

So after looking at both H41's, I found the one I just installed did not have the large lock washer installed. With it installed it allows the shifter to shift to low range without hitting the trans housing. It appears to be "ok" now. I repaired a section of frame near the drivers rear spring hanger and built a new down pipe for the factory exhaust manifold. Turns out the header (that was not leaking) that I took off was better than the exhaust manifold I put on. It leaks like a sive! Good news is the new trans is nice an quiet and appears to shift throught the gears with no problems. I gave up on the exhaust leak and will try a few options later this week.

 

[matzell]

I got the manifold back from machine shop. After taking 50 thousand off it is flat again. Got it all back on and it is tight as a tick! Even added something to the downpipe for future use.

 

[matzell]

After a little rain we wheeled up at the Cove this past weekend. The Orion transfer case with the 4:1 gear set works great with the H41 tranny. First gear was never too low and 2nd gear was a good option too. Nice and slow compression braking for the down hills was nice too.
I had to remove the rubber shift boot so it would stay in high range but it never popped out of low.
I was able to get the IPOR skid plate on just in time for this trip and I may or may not have used it a few times.

I ran over a stick and it took out my rear brake line as it poured down rain on us. The trail quickly turned into a white cap raging river that had water over 1/2 way up the wheels. We made it out and back to camp without issue. Spare parts showed up and we were back out the next day.

Highlight was using the tailgate as designed!

 

[RWBeringer4x4]

I’m bummed I couldn’t make this trip but my truck can’t keep up on the harder stuff anyway (yet).

Any idea why the shift boot would prevent it from engaging the high range and staying locked in? Something your going to look into or are you going to live with it?

 

[Tank5]

I am impressed at how quick you put this together and got it out wheeling already. It looks good. I wish I could move that fast with mine. Nice work!

 

[matzell]

Here is a video of the trails we did on Friday. I had to lead so did not get much time in front of the camera. YES I did drive that rock garden at the start. I turtled it once when the front tire slipped off a rock and had to winch 2-3' but that was it all weekend.

 

[matzell]

I’m bummed I couldn’t make this trip but my truck can’t keep up on the harder stuff anyway (yet).

Any idea why the shift boot would prevent it from engaging the high range and staying locked in? Something your going to look into or are you going to live with it?

I hope to figure it out. I am thinking more adjustment with the shifter but another guy there had one with the AA shifters and I may just buy those.

 

[matzell]

I am impressed at how quick you put this together and got it out wheeling already. It looks good. I wish I could move that fast with mine. Nice work!

I just looked back and saw that I started this in August 2019. I have felt like I have a lot of time in it but have not worked on it everyday. I have a bunch of time in research and thinking of what to do and not do as well. I also tried to plan ahead and have parts ready when I got to that stage to make it go faster. I ran into a couple of issues but overall it came out good and works great to. I am very happy and impressed at what this "little" thing can do and where it goes. I lead two guys on 37's this weekend and although they made the rock garden without winching I think I made some of the other lines better than they did. We all got denied on one very steep hill climb on day two. I hope that video makes it out. It was rocky, muddy, and did I mention steep?

I think I put together a great little package that the common 40 owner could do without too much money and have something they could drive to and from wheeling weekends. One of my friends just did a similar thing. 33 skinnys, air lockers front and rear and an H42/ Orion. I talked him into 3:70 gears since he does drive his on the highway ( he drove down from PA this weekend to VA) He went just about everywhere I did all weekend and had a great time and did really well.

 

[RWBeringer4x4]

I just looked back and saw that I started this in August 2019. I have felt like I have a lot of time in it but have not worked on it everyday. I have a bunch of time in research and thinking of what to do and not do as well. I also tried to plan ahead and have parts ready when I got to that stage to make it go faster. I ran into a couple of issues but overall it came out good and works great to. I am very happy and impressed at what this "little" thing can do and where it goes. I lead two guys on 37's this weekend and although they made the rock garden without winching I think I made some of the other lines better than they did. We all got denied on one very steep hill climb on day two. I hope that video makes it out. It was rocky, muddy, and did I mention steep?

I think I put together a great little package that the common 40 owner could do without too much money and have something they could drive to and from wheeling weekends. One of my friends just did a similar thing. 33 skinnys, air lockers front and rear and an H42/ Orion. I talked him into 3:70 gears since he does drive his on the highway ( he drove down from PA this weekend to VA) He went just about everywhere I did all weekend and had a great time and did really well.

This is ultimately what I’m shooting for, just getting there much MUCH more slowly! I think a H41/Orion/3.70 gears might be the perfect combination on and off-road.

Remind me what you did for a lift?

 

[matzell]

This is ultimately what I’m shooting for, just getting there much MUCH more slowly! I think a H41/Orion/3.70 gears might be the perfect combination on and off-road.

Remind me what you did for a lift?

I used an old new stock Rancho 2 1/2 lift with CCOT shackles, so~3" or so. If I had known I might end up with the Orion I may have gone 3:70 gears as well, but with 33's and 4:10 it does fine at 60-65 without revving too high. I will trailer to most places just because I have the equipment.

 

[RWBeringer4x4]

I used an old new stock Rancho 2 1/2 lift with CCOT shackles, so~3" or so. If I had known I might end up with the Orion I may have gone 3:70 gears as well, but with 33's and 4:10 it does fine at 60-65 without revving too high. I will trailer to most places just because I have the equipment.

I’ve got 7.5R15’s (which should be 32’s, but measure out to like 30.5) and the stock 4.10’s. Most importantly, I have a V8, so I can trudge along at 70 and about 3200rpm and, aside from beating absolutely deafening the engine doesn’t “care.” Really the onus to go to 3.7’s would be to bring the noise and RPM’s down and maybe get the fuel economy up a bit. I don’t have a trailer or a tow rig so anything I can do to make it both street and trail friendly is a plus. That said, 3.7’s are pretty low on the priority list.

 

[BROKEROB1]

I would have said the same thing, Rick... until I swapped in the 3.7 gears. I absolutely love them. They were the last piece of the puzzle, that makes my truck the ultimate wheeler and driver. I refuse to trailer my 40... drive it, wheel it, break it, fix it, repeat!

I‘m so grateful to guys like Rob M who have real mechanical talent, in helping figure some of things things out!

And my last tip for ya... get a set of Air Pod Pros... they are the ultimate 40 road trip (noise canceling) companion

I’ve got 7.5R15’s (which should be 32’s, but measure out to like 30.5) and the stock 4.10’s. Most importantly, I have a V8, so I can trudge along at 70 and about 3200rpm and, aside from beating absolutely deafening the engine doesn’t “care.” Really the onus to go to 3.7’s would be to bring the noise and RPM’s down and maybe get the fuel economy up a bit. I don’t have a trailer or a tow rig so anything I can do to make it both street and trail friendly is a plus. That said, 3.7’s are pretty low on the priority list.