Hi All,
I have been driving my 40 some more lately and I definitely one of the members of the "Orion pops out of gear club."
I have a SOA FJ40 with custom drive shafts. I run 4.88's, H41 and the Orion. On the last few trail runs I resorted to using THREE marine grade bungee cords to keep the tcase lever in position. On steep 4x4 hill declines the case wants to pop out of gear into neutral. I have also experienced it popping out of gear in 2-Hi while on the freekin' highway.
I know that there have been lots of chatter here and elsewhere on this subject. I LOVE the Orion when it is behaving. I have done a bunch of reading and it looks like one should have new or next to new main shafts, shift collars, along with thrust washers, fine spline front output shafts/couplers and detent balls and springs etc. This is all some of the stuff that you need from your existing case to build the Orion.
One of the last posts was from "Peesalot" who said:
"...after many hours of research and many more removing and reinstalling the orion I am of the following opinion:
Use new shift collar
Set shift fork detent screw tight.( past cotter pin completely)
Set load properly on outputshaft ( IMO this is the cause of poppong out of gear )
Make sure you used spacer so input gear does not walk back and forth( also cause of popping out of gear IMO )
I have done all the above and still have popping into N from 2H upon coasting decents with some speed , and once when in low range to N when running in 4th. gear and letting off to coast .
I feel the popping out of gear is a combo of ,
1)worn shift collar
2)walking input gear ( effects the idler slightly which effects high gear ever so slightly but IMO is enough to kick collar out when coasting at speed)
3) Output shaft load set wrong and allowing play between the hi - lo - nuetral dog teeth . So when decending in a coast the input thrusts back( effecting the high gear alignment , the output is thrusting forward further effecting dogteeth alignment. So if you gots play and a worn collar you got popping outa gear.
Mine has a 3/32 play or walk on input and like 12/1000 on the output and it pops . Everything else is checked or done and is right and tight so it has gotta be these factors or , or , or just maybe Marlin's first guess was right and the gear cutter fawked up and the taper on Dogteeth is wrong ..."
I plan on dropping my tranny and Orion and REPLACING WHAT WILL FIX THE PROBLEM. But I have this fear in my head that this may not be enough. IS there anything we are missing? Anyone hear anything from AA instead of
"your shift sleeve and spring are worn out..." I swear someday someone will get seriously hurt by the Orion "wonder transfer case" popping out of gear someday.
There is so much rambling about the Orion all over the place: it would be nice if it was condensed into a "Cliff Notes" book...
Thanks!
Max
I have been driving my 40 some more lately and I definitely one of the members of the "Orion pops out of gear club."
I have a SOA FJ40 with custom drive shafts. I run 4.88's, H41 and the Orion. On the last few trail runs I resorted to using THREE marine grade bungee cords to keep the tcase lever in position. On steep 4x4 hill declines the case wants to pop out of gear into neutral. I have also experienced it popping out of gear in 2-Hi while on the freekin' highway.
I know that there have been lots of chatter here and elsewhere on this subject. I LOVE the Orion when it is behaving. I have done a bunch of reading and it looks like one should have new or next to new main shafts, shift collars, along with thrust washers, fine spline front output shafts/couplers and detent balls and springs etc. This is all some of the stuff that you need from your existing case to build the Orion.
One of the last posts was from "Peesalot" who said:
"...after many hours of research and many more removing and reinstalling the orion I am of the following opinion:
Use new shift collar
Set shift fork detent screw tight.( past cotter pin completely)
Set load properly on outputshaft ( IMO this is the cause of poppong out of gear )
Make sure you used spacer so input gear does not walk back and forth( also cause of popping out of gear IMO )
I have done all the above and still have popping into N from 2H upon coasting decents with some speed , and once when in low range to N when running in 4th. gear and letting off to coast .
I feel the popping out of gear is a combo of ,
1)worn shift collar
2)walking input gear ( effects the idler slightly which effects high gear ever so slightly but IMO is enough to kick collar out when coasting at speed)
3) Output shaft load set wrong and allowing play between the hi - lo - nuetral dog teeth . So when decending in a coast the input thrusts back( effecting the high gear alignment , the output is thrusting forward further effecting dogteeth alignment. So if you gots play and a worn collar you got popping outa gear.
Mine has a 3/32 play or walk on input and like 12/1000 on the output and it pops . Everything else is checked or done and is right and tight so it has gotta be these factors or , or , or just maybe Marlin's first guess was right and the gear cutter fawked up and the taper on Dogteeth is wrong ..."
I plan on dropping my tranny and Orion and REPLACING WHAT WILL FIX THE PROBLEM. But I have this fear in my head that this may not be enough. IS there anything we are missing? Anyone hear anything from AA instead of
"your shift sleeve and spring are worn out..." I swear someday someone will get seriously hurt by the Orion "wonder transfer case" popping out of gear someday.
There is so much rambling about the Orion all over the place: it would be nice if it was condensed into a "Cliff Notes" book...
Thanks!
Max