O R I O N

[Poser]

Thanks Steve, Excellent write up.
Ever considered putting a link in the Tech Links area?

It is in the Frequently Asked Questions list.



I do not have any control over the Tech Links area.
(or if I do, I have no idea how to modify that area)

 

[Tokamak]

Large Hi/Lo Shaft Seal

My Orion kit didn't have the large (1"od) seal for the Hi/Lo shift shaft. (hard to say fast) Called AA and they (Vic) said the larger seal is rare and they only supply the small OD seal. On this forum I have seen a lot of the larger seal.

Does any one know of a subsitute replacement I can buy. Other wise it's off to toyota to order it. On line it is twice the cost of the seal just to ship it.

Went to Toyota and ordered it. Will be here Tuesday. Hope it's the right one. Vic at AA said it was Toy PN 90310-13001.

 

[orangefj45]

Early seal 90313-13001
Later ( larger ) seal 90310-13001

Vic called me about this yesterday afternoon......

Hth

Georg

 

[Tokamak]

Orion Serial Numbers

Thanks for the confirmation of the seal numbers.

I noticed that a lot of the pictures of Orions have serial numbers stamped into the case. Mine does not have a number. What's the deal?

John

 

[orangefj45]

I have built a few that have no serial numbers stamped on them and there are a couple of duplicate serial numbers. I don't think it's a big deal because by now they've done all the upgrades needed and these cases are very trouble free.

Just shipped this one off to a fellow mudder in UT, no serial number. I called AA and asked if they wanted me to stamp a serial number on the case but they weren't worried about it.

Georg @ valley hybrids

 

[southff4]

Can't Wait to see MINE THANKS Georg!

 

[orangefj45]

Good things come to those who wait.....but I'll post a pic of it on here when it's done. Just to tease ya a little!

Georg

 

[Tokamak]

Here's mine bolted up

 

[Irish52084]

I just got my Orion and the Idaler gear and shaft was not installed. I was of the impression that AA did this. Anyone if they were to do this? thanks, Irish

 

[orangefj45]

AA used to install them. I like doing them myself to prevent any possible leakage issues at the idler shaft o-rings.

Hth

Georg

 

[orangefj45]

Here's mine bolted up

Very nice looking combo. Clean setup!!!!

Georg

 

[Tokamak]

Orion Idler

Mine did not come assembled although they said it would. I agree with Georg, I would rather see the orings go in and know they are good.

Just before the oring disappears into the case give it one last push into the groove. There isn't much bevel on the case and it snips a sliver off the oring at the last push.

Funny soft blue orings came with mine. Maybe silicon not buna-n or viton.

John

 

[Cdaniel]

Interesting, my recently aquired unit came with the idler installed

 

[orangefj45]

i don't like the "blue" o-rings now supplied in the kits ........ they're too soft, the diameter is too big by at least 1mm and it's almost impossible to install them without cutting them.
so i buy and install oem o-rings. they're not cheap; about $4 each. but if they help prevent a leak at the idler then it's well worth it to me.
fwiw, i usually apply a very small amount of silicone to the o-rings when i install the idler, no matter what t-case i'm working on. that helps lubricate the o-ring so the idler slides into position easier and it helps seal up the cavity, especially if an o-ring gets inadvertantly cut.

hth

georg


ps: oem part # 90301-27003 same as an early split case

 

[Irish52084]

I also didn't get the shims or Torqo fluid,any one else have this happen? Thanks, Irish

 

[Irish52084]

Just checked I got the Black O rings.

 

[Irish52084]

Sorry about all the posts, Just thought about this. Couldn't a snap tie be used on the O ring to compress it,then push down on the little bit that would be exposed. Just a thought. Also, on the special bolt that come's with the Orion,could the case or the bolt be turned to fit an O ring to help with any leaks from that spot? What ya think? Irish

 

[Blue77FJ40]

What would be wrong with chamfering the case to remove the ultrasharp edges to avoid cutting the o-rings in the first place?

 

[orangefj45]

I also didn't get the shims or Torqo fluid,any one else have this happen? Thanks, Irish

do you mean the thrust washers for the idler gear or the shims for the output shaft?
the fluid was only supplied with the early cases, that stopped a couple of years ago. run 80-90 gear oil.

Sorry about all the posts, Just thought about this. Couldn't a snap tie be used on the O ring to compress it,then push down on the little bit that would be exposed. Just a thought. Also, on the special bolt that come's with the Orion,could the case or the bolt be turned to fit an O ring to help with any leaks from that spot? What ya think? Irish

a zip tie would bunch up the oring right where the "ratchet" mechanism tightens the tie and the oring would get cut for sure there. but it's a good idea to use something similar to a piston ring compressor.

What would be wrong with chamfering the case to remove the ultrasharp edges to avoid cutting the o-rings in the first place?

the cases are chamfered during the machining process.

hth

georg @ valley hybrids

 

[Weber Sarge]

I've looked at these case setups for awhile now with a lot of interest . My preference would be a completed unit with 4:1 low range installed . The short question is this - would it be worth the price to go this route since it's the only basic upgrade available other than seriously lengthening the driveline ?
I sure don't like reading basic issues such as o-rings that get cut during installation creating leaks , after all for the money this shouldn't be an issue . Or, is this just a random problem and most installs are free of issues ??
Sarge