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  #1  
Old 06-02-2013, 02:15 PM
MisledYouth's Avatar
MisledYouth MisledYouth is offline
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Unhappy Any Orion wizards in here?

I got my 40 back from Proffitt's in July of last year, and went immediately to Moab afterword. I'm still working overseas so I have to smash all of my fun into 35 days. Anyway, I was having trouble getting my Orion 4/1 to shift, so I rang them up and we got it sorted out. It worked GREAT until I took it out to Moab in early April on another break. Basically, it would gear down when I shifted, but the front drive would not engage. So I tooled around in 2WD the whole time on Hell's and Gold Bar and so on.

I'm not the most mechanically minded individual, and now I'm gone most of the time, so I'm having my brother run around trying to get this thing looked at before I get home around July/August. He's close with the guys at High Country as he's worked for a couple of their buddy shops in the area and I was just going to have him take it there. I figured I'd check here first though before I take it in.

SUMMARY: ORION 4/1 shifts and gears down, but front drive will not engage. Also, there is not much of a noticeable difference between hi and lo range (both are basically lo).

If anyone has any ideas or shop recommendations, I'm all ears. Thanks guys.

GRATUITOUS 2WD PLAY SHOT!!!!
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Zach Feiler | Littleton, CO
3rd Battalion 5th Marines India Company 2005-2009
"Get Some"

1979 FJ40 - "The Phun Express" - Smurf blue
- 5.3 Vortec - 4L60E - Orion 4:1 -SOA front / 4-link rear - FJ60 axles - ARB's - 4.88's - 37's

1999 UZJ100
- factory locker/ARB front - 285/75r16 Duratracs - Slee 2.5" Heavy Kit - Slee Blueberry/Warn VR10000 - Slee tube sliders - EMS cat-back
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  #2  
Old 06-02-2013, 03:28 PM
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Corbet Corbet is offline
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I'm not an Orion guy but I'd take it to Justin at Red Line. That's probably up his alley.
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  #3  
Old 06-02-2013, 04:34 PM
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FJBRADY FJBRADY is online now
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X2 for Justin at Redline.
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  #4  
Old 06-02-2013, 06:21 PM
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There physically isn't a way for either shift action to in fact move but not engage (shift) without something being either bent, broken or missing. I'd suggest that the case be dropped and inspected. At a minimum, pull the top cover and inspect the hi-low shift linkage, fork and sleeve. Also pull the 4WD linkage and inspect the 2-4WD fork, sleeve and shafts. They are extremely straightforward and while there are numerous tricks to make them work better, you should at a minimum be able to see why it isn't shifting. Totally shooting from the hip but I'm suspecting this is an external linkage issue, perhaps as a result of a super tight shift detent on the Orion, possibly bent a linkage or fork?
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  #5  
Old 06-02-2013, 11:28 PM
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Thanks folks. I'll see if they've got time to drop it off at Redline. That was my first choice, but I've been running them all over the place as it is.
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Zach Feiler | Littleton, CO
3rd Battalion 5th Marines India Company 2005-2009
"Get Some"

1979 FJ40 - "The Phun Express" - Smurf blue
- 5.3 Vortec - 4L60E - Orion 4:1 -SOA front / 4-link rear - FJ60 axles - ARB's - 4.88's - 37's

1999 UZJ100
- factory locker/ARB front - 285/75r16 Duratracs - Slee 2.5" Heavy Kit - Slee Blueberry/Warn VR10000 - Slee tube sliders - EMS cat-back
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  #6  
Old 06-03-2013, 10:05 AM
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Air Randy Air Randy is offline
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Are you using the stock shift linkage? If so, try ordering the twin stick shifter kit. My Orion was horrible to shift and popped out of low range occasionally so I installed the twin stick shifter. Never had another issue with it.
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  #7  
Old 06-03-2013, 12:26 PM
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Is everything hunky dory with your front driveline? No broken birfields, differential, hubs, etc.?
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  #8  
Old 06-03-2013, 01:53 PM
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MisledYouth MisledYouth is offline
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I do have the twin stick. As far as I know, birfields and diff should be good. I'm not sure about the Aisin hubs. I've never really had a problem with them, and I'm not sure how I would be able to tell. I can turn the driveshaft with my hands when it's in 2wd with the hubs free, and then if I lock the hubs I can no longer turn the driveshaft. The problem was that there was no power going to the front when I was actually in 4 and driving. If I was home right now, I would have no issue just bombing down to Redline, but I have to keep it convenient for the people I'm running around. I'll see if my brother is willing. I'm sure he wouldn't mind checking out the shop too.
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Zach Feiler | Littleton, CO
3rd Battalion 5th Marines India Company 2005-2009
"Get Some"

1979 FJ40 - "The Phun Express" - Smurf blue
- 5.3 Vortec - 4L60E - Orion 4:1 -SOA front / 4-link rear - FJ60 axles - ARB's - 4.88's - 37's

1999 UZJ100
- factory locker/ARB front - 285/75r16 Duratracs - Slee 2.5" Heavy Kit - Slee Blueberry/Warn VR10000 - Slee tube sliders - EMS cat-back
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  #9  
Old 06-03-2013, 01:55 PM
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Someday when I'm home more often and had time, I'm going to take some time and absorb all of the mechanical Cruiser knowledge I can.
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Zach Feiler | Littleton, CO
3rd Battalion 5th Marines India Company 2005-2009
"Get Some"

1979 FJ40 - "The Phun Express" - Smurf blue
- 5.3 Vortec - 4L60E - Orion 4:1 -SOA front / 4-link rear - FJ60 axles - ARB's - 4.88's - 37's

1999 UZJ100
- factory locker/ARB front - 285/75r16 Duratracs - Slee 2.5" Heavy Kit - Slee Blueberry/Warn VR10000 - Slee tube sliders - EMS cat-back
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  #10  
Old 06-03-2013, 06:31 PM
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Rzeppa Rzeppa is offline
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Not sure if this helps, but the split case on my 60 wouldn't stay in 4WD, the front drive kept popping out. They put it on the lift at Safari LTD when I stopped in there on the way to Moab and dorked around with the linkage and now it works great. They explained to me that there is just enough play in how the linkage is bolted in that it can keep the collar from engaging the splines in the output shaft.

Before I went there, I had chatted with Jeramiah about it and he suggested that maybe the spring that holds the ball in the shaft detents was worn out and for sure, it didn't have the positive click into and out of front drive like my other cruisers. So I added some preload to the spring by putting a screw in the spring, the head of the screw acts as a spacer. The spring was around .7" before the spacer and about .8" afterwards, and made a noticeable difference in how that detent felt when I shifted into and out of front drive.
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Last edited by Rzeppa; 06-04-2013 at 11:40 PM. Reason: dimensions
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