Land Cruiser manual - Advance Adapters

Ordering Ordering Ordering an an an Orion Orion Transfer Transfer Transfer Case:
Case:
ORION4 4.0:1 fits vehicles with 10 or 16 spline inputs
ORION3 3.0:1 fits vehicles with 10 or 16 spline inputs
When ordering an Orion we also need to know the following information:
Orion Gear Ratio - 3.0:1 / Orion3 or 4.0:1 / Orion4
Input spline needed - 10 spline P/N O70010 OR 16 spline P/N O70016
Twin Stick - See page 26
Hardware needed - O10220 stock 3 speed, O10221 stock 4 speed, O10222 when using our one of our adapter kits
Note: When using either Orion transfer case with a Toy Box, the Orion will require modifications to the top of the case for the Toy Box shifter rail.
Transfer Case Shafts - We do carry stock replacement output shafts for the Orion transfer case. We have found that most
stock transfer case output shafts have excess wear on the gear journals. These new shafts will provide a closer tolerance installation
for the Orion gears.
P/N O40500 - T/Cs up to April 1975 P/N O40501 - T/Cs April 1975 to July 1980
Orion Orion Orion Standard Standard Duty Duty Transfer Transfer Case Case Points Points of of Concern: Concern: The success of an Orion Transfer case installation
is dependant on the condition of the necessary components that are to be reused from your stock case. Some of the most critical
components that require your attention to detail are as follows:
HI/LOW CLUTCH SLEEVE - Inspect for excessive or worn splines. The splines should not be tapered throughout the sleeve
width. You will notice the “V” looking tapers or “boat tails” only at the last .070” to the contact sides of the sleeve towards each
gear. If you need a new sleeve, P/N O50010
SHIFT FORK LOCK BALL AND COMPRESSION SPRING - We have provided a new ball, spring, and brass set screw to be used
for your installation. The ball provided measures 10mm and will tighten up the tolerance in the shift fork bore. We have also
provided a new spring which has a greater holding capacity than an older worn out spring. The new brass set screw will take
the guess work out of setting the tension on the spring and ball inside the new shift fork. The brass set screw should be installed
with a bit of Loctite to retain it, and the hex should be seated completely to the shift fork.
P/N P/N O60050 O60050 - 10mm Ball P/N P/N O60051 O60051 - Shift Fork Spring,
P/N P/N O60052 O60052 - Set Screw P/N P/N O60040 O60040 - New Shift Rail
P/N P/N O60041 O60041 - O-RINGS
THRUST WASHERS - The thrust washers are an important and critical area when installing the Orion gears on your Toyota shaft.
The first step is to inspect the transfer case output shaft for excessive wear and to make sure the gears fits the shaft. If your shaft
is worn excessively, the gear will be a loose fit or will be able to wobble. If this is the case with your shaft, replace it. We do offer
replacement shafts.
If the shaft is in good shape, then proceed. The end play of the gear on the shaft must be set. The new Orion gears are the same
width as a stock gear set. Gear end play should be set at .008"-.012". We now include two new thrust washers to help set up
the transfer case with the correct end play. These thrust washer are stepped. One side has a recess of .015" - .017" and the
other side of the washer has a .008" - .010" recess. So by using one side or the other of the washer or using your stock washers,
you should be able to get close to the required tolerance. P/N P/N O60080 O60080 (2 required)
38 ORION TRANSFER CASE APPLICATIONS