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Old 05-27-2007, 11:09 AM   #1 (permalink)
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Orion transfer case install

I think I posted this in the wrong forum originally.

I spent all day at my buddy's house installing an Orion T-case in his 1976 FJ-40. It's in and working, but I have a few questions.

First, he also has a 1970 FJ-40 with a Chevy 350 V-8 conversion. Being a Jeep guy (cough, cough), it didn't cross my mind to look at the Orion case before digging into the case on the '70 - which was the original vehicle that the Orion was going to go in. Well, we got the '70 case out only to find that it wasn't an original FJ case. It didn't have the parking brake drum assembly on the rear driveshaft, and it was a split case design. Also, the tranny output shaft was a slightly larger diameter than the one on the '76. So, what t-case did we disassemble? I'm thinking maybe a Toyota truck? Is there a popular tranny/t-case swap that works with the Chevy V-8 conversion that this might be?

Second, there was no way for us to measure the bearing preload on the t-case when we finally got the Orion together. We adjusted it with the shims provided so that we had to make just a little effort to turn the shaft. How critical is this preload and should I be concerned?

Overall, it was a fairly involved swap. Jeep t-cases take just six bolts (NP-231) and they drop out. The bearing on the tranny output shaft was a pain to get out so that the t-case could be removed. We eventually used a slide hammer.

The low range is pretty low, making the effort worth it.
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Old 05-27-2007, 12:04 PM   #2 (permalink)
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Was it centered output to the rear, If so it's likely a mini truck case. Offset to the passenger side then probably a late~~~80 or so and up cruiser splitcase.
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Old 05-27-2007, 01:37 PM   #3 (permalink)
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Was it centered output to the rear, If so it's likely a mini truck case. Offset to the passenger side then probably a late~~~80 or so and up cruiser splitcase.
Offset to the rear passenger side. So, post 1980 FJ t-case?
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Old 05-27-2007, 01:52 PM   #4 (permalink)
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That'd be my guess. Good strong case, later ones are even better, larger idler shaft or something to that effect. They came on late 40s and all 60s and 62s. I'm not sure on the date they went into the 40. I actually don't know much about them except there's 3.4 or so gears available for them from Marks in Australia. I believe AA distributes them in the US.

It seems most people on the board are out playing this weekend, you'll get more action tomorrow or Tuesday I'm sure.
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Old 05-27-2007, 06:31 PM   #5 (permalink)
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If I understand you, you assembled the Orion using the parts needed from the transfer case that was in the Cruiser already?

If so it is a one piece 63-79 FJ 40,45,55 case 'cause you can't use any other case to build an Orion.
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Old 05-27-2007, 06:42 PM   #6 (permalink)
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If I understand you, you assembled the Orion using the parts needed from the transfer case that was in the Cruiser already?

If so it is a one piece 63-79 FJ 40,45,55 case 'cause you can't use any other case to build an Orion.
Butch
He has two Cruisers - a '70 and a '76. We built the Orion using the case from the 1976 FJ. It was all original. The case from the 1970 is what's up in question and couldn't be used since it was obviously swapped in with the V-8 conversion.
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Old 05-29-2007, 10:09 AM   #7 (permalink)
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Originally Posted by Capt. Nemo View Post
Second, there was no way for us to measure the bearing preload on the t-case when we finally got the Orion together. We adjusted it with the shims provided so that we had to make just a little effort to turn the shaft. How critical is this preload and should I be concerned?
uhmmm, yeah it's important. if the pre-load is too loose then you'll get premature bearing wear along with improper gear tooth mesh which can end up damaging the gears as well.

iirc, the instructions show you how to check bearing preload on the bench.
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Old 05-30-2007, 12:31 AM   #8 (permalink)
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the fj40 owner

I'm the guy with the two fj's. Turns out the 70 does have a 82 split case and the 4 speed. I bought it thinking it as a 77. Preload was 10-20 pounds. I think it is in that range. Question? The Orion case is cast iron and adds a bit of weight (lots). Would it be necessary to put a cross member under it? Seems like a lot of weight hanging off the back of the tranny?
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Old 05-30-2007, 09:38 AM   #9 (permalink)
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what transmission are you running?
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