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O R I O N

Discussion in '40- & 55-Series Tech' started by Poser, Feb 23, 2007.

  1. Poser

    Poser Oh...Durka Durka Durka. s-Moderator Supporting Vendor

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    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: Dec 14, 2011
  2. 1Fine40

    1Fine40 Rust Buster SILVER Star

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    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!
     
    Last edited: Feb 23, 2007
  3. peesalot

    peesalot

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    #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.
     
  4. calstyl2

    calstyl2

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    #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
     
  5. cruiserhead

    cruiserhead

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    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.
     
  6. treerootCO

    treerootCO Where are my keys?! SILVER Star

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    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.
     
    Last edited: Apr 20, 2007
  7. meat

    meat

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    #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.
     
  8. green73

    green73

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    #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.
     
  9. chattfj40

    chattfj40

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    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.
     
    Last edited by a moderator: Feb 27, 2007
  10. wapitidon

    wapitidon

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    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.
     
  11. greenfox

    greenfox

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    #303 4:1 new cut gears shift fork,new coller, cant remember the rest?
     
  12. coiled40gary

    coiled40gary

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    #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
     
  13. Wheelin4

    Wheelin4

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    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.
     
  14. Degnol

    Degnol

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    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:bounce: :bounce2: except the driver:doh:
     
  15. lemon

    lemon

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    #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.
     
    Last edited: Mar 14, 2007
  16. peesalot

    peesalot

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    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.
     
  17. lemon

    lemon

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    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.
     
  18. bunnyhill

    bunnyhill

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    #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
    :banana:
     
  19. 65swb45

    65swb45 Supporting Vendor

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    #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!:eek:

    #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.

    :cheers:
     
  20. Toyland4x4

    Toyland4x4

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    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.