Advance Adapters 7169380 - Manual

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components
will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly
recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components. We
recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals are normally
available at automotive dealerships and parts stores.
KIT CONSISTS OF:
No. Qty Description
ADVANCE ADAPTERS INC. P/N: 716938
P.O. Box 247, 4320 Aerotech Center Way New Item: (03/11)
Paso Robles, CA 93447 PAGE 1 OF 2
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 06-10-12
FJ60/62 34 & 38 MM CLUSTER PIN 4:1 GEAR SET
1. 1 CLUSTER GEAR
2. 1 19 SPLINE INPUT GEAR
3. 1 LOW RANGE GEAR
4. 1 HIGH RANGE GEAR
The 4:1 low gear set offers you some gearing options without
swapping axles or drivetrain and requires no drive shaft modifica-
tions. The kit does not include bearings or new seals. We do offer
a rebuild kit, P/N 401419.
We recommend obtaining a Toyota service manual for the proper
disassembly procedures and the proper torque speciations during
reassembly.
Follow the service manual procedure to remove the transfer case from the transmission. Thoroughly inspect the transfer case
to determine the condition. Overhaul if necessary to insure the quality of your new gear installation.
The installations of the 4:1 gears requires some machining to the rear half of the Toyota transfer case. The machining should
be performed at a machine shop to ensure the proper case clearance is obtained without removing to much case material and
weakening the case.
This gear set is designed for the 38MM cluster pin case, however; we offer a stepped cluster pin that works for the 34MM case
and uses this same gear set. The cluster pin kit for the 34MM case is P/N 716934.
Note: This Gear set will also alter your high range ratio. The high range ratio will now result in a 10% underdrive
Cluster gear clearance: The large end of the cluster is 6.665" in diameter. The case needs to be clearance for this gear. The back
half of the case requires modifications. Measuring from the mating surface of the rear case half, 1.30" deep and a clearance diameter
of 6.685" is what needs to be clearanced for the gear. The gear interferes with the two lower bosses.
Low gear clearance: This gear requires a bit more modifications to the rear case half for gear clearance. The gear diameter needs
to clear 7.353" all the way to the bottom of the case half. The modifications to the case for this gear removes material ,several of
the internal bosses, and from the shift rail boss.