O R I O N (20 Viewers)

[peesalot]

It has to do with the high speed gear oscillating on the main output shaft. Sometimes a new main shaft will clear it up but you may need a new bushing in the hi speed gear. At least that's what worked for me.

 

[fj55tlc]

Thanks for the replies. I am positive it is not the linkage, I have tried that. I was leaning toward the main shaft and bushing. I will look into that.

 

[orangefj45]

Fwiw, I have the shafts and bushings in stock. Along with everything else to rebuild these t-cases.

Georg @ Valley Hybrids

 

[pardion]

Just test drrove mine, got it from Georg ,4 to 1, put together myself, used factory hi and lo output shaft washers, added Georg's front nose cone stiffiner ring. Also I built a new rear transfer case mount that cushions and supports the T/C from the middle, not from the frame. 383 stroker, SM420, 10 degree steel plate adapter, and the shift linkage works well. I will have over 100 day's on the Rubicon Trail this year so any production of this mount will wait till after at least 10 trips. John Pardi

Well, 10 Rubicon Trail trips so far this year, 55 days. Orion has worked GREAT! No popping out of gear with stock floor shift linkage. The rear support still looks like brand new, I do notice the shifters on the floorboard floating nicely in their boots. 10 more planned trips this year/50 days. See you on the trail, John

 

[ToyRoverlander]

Mine has been fitted now for just over a year. Has about 6.000miles on it I guess.. Works like a charm, LOVE it! The low gearing is awesome! Putting it together wasn't difficult at all.
No case number in mine...

 

[youngdogs]

Georg,

I just wanted to let you know that the Orion you put together for me has been working great. We ran the Rubicon this past weekend and the low crawl ratio in the pig was wonderful. You and Don at Valley Hybrids do fantastic work!

 

[orangefj45]

Righton Jake!!!!

 

[orangefj45]

Just finished this Orion-H41 combo for a fellow mudder.

Georg @ Valley Hybrids

 

[orangefj45]

Another one on its way to a fellow mudder.




Georg @ Valley Hybrids

 

[ToyRoverlander]

What kind of 90degree elbow is that you use for a breather on the top cover? Is that the same thread as axle breathers?
Mine leaks oil there from the original breather...

 

[orangefj45]

1/2" pipe 90 deg to 3/8" barbed fitting from the local hardware store for $6.
You have to re-tap the top cover to 1/2" pipe but the existing thread is close enough to just run the pipe tap into .....

Here to help

Georg @ Valley Hybrids

 

[DPV7070]

Another one on its way to a fellow mudder.




Georg @ Valley Hybrids

Hey that one's mine!

This is like seeing an ultrasound of your first kid!!!

P.S. Don't tell my wife I said that...

Thanks Georg!

 

[orangefj45]

Hey that one's mine!

This is like seeing an ultrasound of your first kid!!!

P.S. Don't tell my wife I said that...

Thanks Georg!

Thank you!!!!!!!

Georg @ Valley Hybrids

 

[orangefj45]

Mine has been fitted now for just over a year. Has about 6.000miles on it I guess.. Works like a charm, LOVE it! The low gearing is awesome! Putting it together wasn't difficult at all.
No case number in mine...

Why are you running the oil cross-over hose?!

 

[ToyRoverlander]

Thanks. I'll have a look for one of those elbow fittings at our local hardware store. Would be nice to not have it leaking all over the case.


I ran that hose for a very short time as I didn't have the correct plugs. I must have chucked them away when I installed that hose a few years back. Got the plugs in it now as the hose is not longer needed as the output seal has been replaced with the installation of the Orion.

 

[laddfj]

Have been reading through a bunch of the threads on mud and was hoping for some direction.

I picked up a 72 FJ40 a while back that had a tbi 350, th350, AA and stock 3 speed transfer case.

I am now in the process of installing a gen iv 5.3L from a 2007 tahoe, an nv4500 from a 94 chevy and then as I contemplate putting that setup in front of my stock transfer case, I figure I am just asking for problems. We are not hard core off roaders but we do go to Moab a few times per year and do other offroad trips. I am not building a crawler, more just a capable offroader that will be reliable for probably 60-70% road time. Currently has stock axles with disc on front and back. 4 inch lift but still spring under.

Obviously where I am stuck is with the adapter and transfer case. Would you recommend the Orion? Would it work with the advance adapter from the nv4500 to the stock TC? I think the AA adapter is 50-0211.

Any thoughts or input would be really helpful.

 

[Mace]

orion would be a perfect tcase for that setup.

 

[orangefj45]

Have been reading through a bunch of the threads on mud and was hoping for some direction.

I picked up a 72 FJ40 a while back that had a tbi 350, th350, AA and stock 3 speed transfer case.

I am now in the process of installing a gen iv 5.3L from a 2007 tahoe, an nv4500 from a 94 chevy and then as I contemplate putting that setup in front of my stock transfer case, I figure I am just asking for problems. We are not hard core off roaders but we do go to Moab a few times per year and do other offroad trips. I am not building a crawler, more just a capable offroader that will be reliable for probably 60-70% road time. Currently has stock axles with disc on front and back. 4 inch lift but still spring under.

Obviously where I am stuck is with the adapter and transfer case. Would you recommend the Orion? Would it work with the advance adapter from the nv4500 to the stock TC? I think the AA adapter is 50-0211.

Any thoughts or input would be really helpful.

Your other option would be to go with a split case from a later cruiser. They're strong, quiet and just a better case IMHO. That's if you want stock gearing in the Tcase. With that setup you'll be right around 60:1 in low. That's enough for most places.
If you want lower gearing, then you could run the Orion or a split case with 4:1 gears in it. They'll both work.
But I wouldn't run a stock case if it'll be mostly street driven and you want to run the stock gearing.
Just my two cents worth ......

Georg @ Valley Hybrids

 

[laddfj]

But I wouldn't run a stock case if it'll be mostly street driven and you want to run the stock gearing.
Just my two cents worth ......

Georg @ Valley Hybrids

Georg,

Thanks for the response. I have been looking for a split case but have been unsuccessful to this point. I didn't understand the last part of your response as quoted above. Mostly street you "wouldn't" run a stock case? Can you explain?

Ladd

 

[orangefj45]

Stock cases are a lot weaker than split cases. They're also usually much noisier. That's due to their age and the fact that the output gears are supported by bushings on the main/output shaft. Those bushings are fairly narrow and allow the gears to canter. And that's why they make noise.
The bushings in the split cases are much wider and the main shaft journal where the gears ride is a wider diameter.
Here to help
Georg @ Valley Hybrids