Advance Adapters Orion Transfer Cace - 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.
ADVANCE ADAPTERS INC. P/N: Orion
P.O. Box 247, 4320 Aerotech Center Way New Item: (06/04)
Paso Robles, CA 93447 PAGE 1 OF 15
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 04-19-05
ORION TRANSFER CASE
Assembly & Disassembly
The Orion was created to replace stock transfer cases built between the years of 1963 and July of 1980. This case
replacement is the same external width, eliminating driveline modifications; however, the drain plug may be
approximately .500" lower than a stock case. The supplied 4:1 gear set replaces the existing gear set except for the
P.T.O. gear or P.T.O. spacer sleeve. It is required that you reuse your stock fasteners, front and rear housings,
retainers, shafts, clutch sleeves, and cover plates from your original transfer case. You are supplied a full rebuild kit
to replace all bearings, bearing cups, O-rings, seals, and gaskets. Shims for the rear output shaft retainer are also
supplied to set the bearing pre-load.
Do not discard shims, washers, sleeves, and spacers from yokes and
shafts. Throughout the disassembly section, reference will be made to items that may be discarded. Attached you
will find 3 different illustrations referring to each component by our common terms. We have also provided a web
site address to an interactive identification page @ www.advanceadapters.com/orion.html providing
actual photos of each component included in your Orion kit. In addition, this site address will include the
colored version of this instruction sheet.
Although this instruction sheet will initiate the steps to install the Orion, it is advised that you obtain a shop or repair
manual that covers your specific application.
Tools required:
Safety Glasses
Metric drive sockets
Metric wrenches
#10 hex bit
Foot Pound Torque Wrench (Torque Range of 10-125 ft./lbs.)
Drift Punch for both Hi and Low Shift Rail and 4 speed stake nut
Dead Blow Hammer
Pliers
Press (hand press)
Universal Puller for stock 3 and 4 speed transmissions
Flat Head Screw Driver
"A” kits (Bolt pack #400222) will also require:
5/8” socket
1-1/4” socket
3/8” hex bit
Note: When using the Orion transfer case
with a Marlin Toy Box, the Orion requires
modifications to the top of the case for the
Toy Box shifter rail. A special machined
case can be ordered from us with this
modification,
P/N O20001
.