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Atlas manual 2013.p65

1. eee 22 23 Custom Build 2 Speed Chart s sus 7 Rear Tailhousing amp Front Output Options 24 25 Custom Build 4 Speed Chart esses 8 Yoke Options amp Interchangeable Yokes 26 27 Atlas Adapter Selection Chart 9 10 Speedometer Options amp Low Range Switch 28 30 Front Input Shaft Applications Shifter Options 2 Speed amp 4 Speed 31 33 Inout Shait Ching COUE icon Essen Atlas Bolt Torque Specifications 20 SAM a I2 Common Installation Mistakes 34 Jeep amp Dodre 23 SORE serene 12 13 Installation Procedures GM amp Dodge 27 SPINE emilandin 14 Lubrication amp Prepara oi ae 35 36 FOU I5 Final Installation Lord 2 SPINE cicesteie nadie tees bete tipp tale ed UM 15 Driveline Modifications cesses 37 Ford 3 1 SPIRE edese aoreet cii d duse 16 Breather Installation LLL 38 Ford 34 SPIRE leaks 16 Speedometer Installation eee 38 39 CNE TOSSDIIDE soer r a E AE 16 Driveshafts Crossmember amp Lubrication sss 39 GM 27 Spline DM M I ICTU MN IPIE CMM E 17 18 Operating The Atlas GNM o2 M c 19 Shifting amp Shifter Positions sss 40 20 Operating Con
2. shown Note The information on years and models of the 4L80E 32 SPLINE transmission mentioned in the above section was obtained GM from various sources You should always verify what your transmission is equipped with before beginning a conversion especially with the 4L80E transmission 6L80 2 amp 4WD 6 speed automatic is also a 32 spline transmis sion This transmission can be used with our 50 9600 kit The VSS tailhousing option would provide the GM computer the speedometer signal for this application GM NV4500 4WD The GM NV4500 4WD transmission can also be coupled to the Atlas The stock GM adapter housing has the right index diameter for the transfer case however the bolt pattern is incorrect We have found it easier to use a stock Dodge tailhousing or our replacement Dodge housing P N 51 0205 Either one of the 6 300 long adapters coupled with our 1 5 8 spacer adapter Part No 51 0220 allows you to use the stock GM 32 spline output shaft This casting will not fit the GM harmonic balancer a spacer tube must be used to replace the balancer on this application GM Inputs Since all of these transmissions are used in larger vehicle applications we have had requests for upgrade options on the Atlas One limited upgrade offered for these transmissions is the heavy duty Atlas input This was developed for some applications that had an increase in horsepower and needed extra strength The heavy duty input is not n
3. FORD ZF 4WD TRANS STOCK 1 5 7 31 FORD C4 3 SPEED TRANS STOCK 5 8 28 REPLACING A BRONCO DANA 20 GM MUNCIE 4 SPEED 50 6000 2 3 7 23 FORD C4 3 SPEED TRANS 50 8 100 3 23 10 CASE LENGTH 5 ADAPTER ALL OTHER VEHICLES NP203 ADAPTER 50 8810 10 SHORTY C4 FORD TRANS 50 2903 2905 27 GM ZF 6SP S6 650 TRANS SEE PAGE 14 29 ALLISON 1000 TRANS SEE PAGE 14 29 TACOMA TRANS 23 SPLINE 50 5710 23 FORD AOD EARLY 4SP 4W D STOCK 1 5 7 31 TACOMA TRANS 26 SPLINE 50 5711 23 1987 amp EARLIEER 2 X D TRANS 50 2902 37 23 POW ERGLIDE automatic 50 9200 27 FORD AOD LATE 4 SP 4WD STOCK 1 57 31 NISSAN TITAN automatic 50 1114 32NT 1988 amp UP 2WD TRANS 50 2901 3 7 23 Toyota Crawler Box 50 5915 23 FORD C6 3 SP TRANS STOCK 1 5 7 31 to Atlas Case 20 CASE LENGTH FORD EXPLORER RANGER BRONCO II STOCK 5 25 1980 11 JEEP AUTOMATICS STOCK 15 210r23 1 2 4 6 7 8 THIS KIT USES A SPUD SHAFT USES A STOCK 2WD OUTPUT SHAFT UP TO THE TRANSMISSION ADAPTER THIS KIT SHOULD BE USED IN CONJUNCTION WITH A 700R KIT THE CASTING IN THIS KIT ONLY HAS ONE ROTATION AVAILABLE THIS TRANSMISSION IF CURRENTLY ADAPTED TO A BRONCO DANA 20 TRANSFER CASE CAN USE AN ATLAS 28 SPLINE TRANSFER CASE AS A DIRECT BOLT OUTPUT SHAFT MAY NEED TO BE SHORTENED OR A SPACER ADAPTER MAY NEED TO BE USED See Page 10 3 5 NEW OUTPUT SHAFT MUST BE INSTALLED USES A STOCK 4WD OUTPUT SHAFT 9 THE OUTPUT SHAFT MUST BE SHORTENED TO BEA FLUSH STICKOUT WITH THE BAC
4. This stock transmission bolt pattern is found on transmissions that were originally bolted to a Dana 300 transfer case with a stock case rotation of 35 degrees This stock transmission bolt pattern is also found on some Jeep transmissions when bolted to a New Process transfer case that had a stock rotation of 23 degrees Atlas 2sp Left Drop Atlas 2sp Right Drop STD or Flat Case Rotation STD or Flat Case Rotation 17 0 degrees 4 0 degrees NEA 18 degrees 38 20 degrees 29 degrees Atlas 4sp Left Drop Atlas 4sp Right Drop Possible Rotations Possible Rotations degrees 5 degrees degrees 12 degrees degrees 19 degrees FOOT OF CASTING OR TRANSMISSION degrees 25 degrees VIEW FROM REAR OF degrees CASTING OR TRANSMISSION ROTATION OPTIONS OPTION 2 This stock transmission bolt pattern is found on some Jeep trans missions when bolted to a New Process transfer case that had a stock rotation of 13 degrees Atlas 2sp Left Drop Atlas 2sp Right Drop TD or Flat Case Rotation 3 degrees degrees CENTERLINE OF HOUSING 21 degrees degrees 28 degrees 35 degrees Atlas 4sp Left Drop Atlas 4sp Right Drop Possible Rotations Possible Rotations degrees degrees 14 degrees degrees 21 degrees degrees mE FOOT OF CASTING OR TRANSMISSION 28 degrees degrees VIEW FROM REAR OF CASTING OR TRANSMISSION degrees OPTION 3 This bolt pattern is found on most of our adapter housings If you are currently using one o
5. USE 1 SPACER RING TO SET CORRECT STICK OUT Atlas 2 Speed Input Ford ZF 5 speeds work fine and are equiped with a 31 spline output shown however the 6 speed ZF diesel will not since Ford used a 24 spline on this transmission 31 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop A31 Stickout length is the length that the shaft protrudes from the rear ofthe transmision with the Atlas 4 Left Drop A431L adapter installed The measurement is the length that Atlas 4 Right Drop A431R e the Atlas will accept FORD 34 SPLINE The 34 spline Atlas was designed to fit the 2004 amp newer 5R110 Torqueshift transmission This 4WD transmission has the speed sensor in the transmission tailhousing so when ordering the Atlas tailhousing a speedometer hole plug is required The 2003 2009 5R110 torqueshift is a 5 speed automatic that was used in the E250 350 and F250 450 6 0 amp 6 4 Diesels The gear ratios are 3 09 2 20 1 538 1 096 1 00 712 amp R2 88 To install an Atlas using the stock 4WD tailhousing you will be required to use a 1 spacer P N AS 0404 34 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop Stickout length is the length that the shaft protrudes from the rear of the transmision with Atlas 4 Left Drop 5 the adapter installed The Atlas 4 Right Drop measurement is the length that the At
6. modify a TH400 adapter to work on the 4L80E transmission The early 4L80E transmission up to 1995 is normally equipped with an internal reluctor ring on both the transmission input shaft and output shaft The computer takes both of these readings for the proper shifting and operation of this transmis sion We have always ignored the reluctor ring requirement for this transmission since it is internally regulated We have now learned that the rear reluctor ring is not always installed into the transmission The basic rule of thumb is 4WD transmissions up to 1996 should have a rear ia ae UPS ona MAN reluctor ring in the main transmission case All 2WD transmissions should have the rear reluctor in the main transmission case The 1997 amp newer 4WD 4L80E y transmissions have a sensor provision however the reluctor ring in the transmis 72 sion is left out Since this transmission is expensive to rebuild and have a reluctor 727 f installed we now offer a reluctor ring on the adapter housing The reluctor on SEN the adapter for a Atlas 2 speed is P N 50 6409 and for the Atlas 4 speed is 77 L P N 50 6410 These kits will always provide a 1 to 1 reading on the out put even if the transfer case is in low gear The VSS reluctor in the tail housing is also an option but it would require a low range switch to be C integrated into the computer system NAN A NN NNI 1 r 1 963
7. 4 SPEED O D STOCK 5s 310R28 GMTH400 4WD TRANS AS 6401 5 32 10 25 CASE LENGTH 4WD trans SHAFT STICKOUT OF 1 5 NOTE 9 FORD amp JEEP T98 4 SPEED 50 7503 3 7 23 GM TH400 4W D TRANS AS 6401 amp 32 11 87 CASE LENGTH 3 25 ADAP SHAFT STICKOUT OF 2 5 NOTE 9 AS 0404 5 JEEP T18 4 SPEED 50 7502 3 7 23 GM 4L80 amp 4L80E 4SP TRANS 51 6408 amp 32 11 87 CASE LENGTH 3 25 ADAP USE GM 4WD SHAFT NOTE 9 see Page 19 5 FORDT184 SPEED 50 7500 3 87 23 GM 700R 4L60 O D 4 SPEED 50 9102 3 23 11 87 CASE LENGTH 3 25 ADAP 23 375 CASE LENGTH 2 X D TRANS FORD T19 4 SPEED 50 6501 3 8 7 23 GM 700R 4L60 O D 4 SPEED AS 9111 27 11 87 CASE LENGTH 3 25 ADAP 23 375 CASE 4W D TRANS 5 FORD NP435 4 SPEED 50 3801 3 8 7 23 GM 4L60E 2W D amp 4W D 50 0404 3 23 10 87 CASE LENGTH 4 25 ADAP 23 375 CASE LENGTH 1980 to 1986 STOCK STOCK 23 GM 4L60E 4W D TRANS AS 9111 27 JEEP TRANSMISSIONS ADAPTER 23 375 CASE LENGTH 5 10 1987 amp NEWER STOCK STOCK 7 21 OR 23 GM 4L60E 2WD 50 0405 amp E 23 JEEP TRANS 21 SPL OR 23 SPL ADAPTER W REMOVABLE BELLHOUSING 50 9102 3 GM NV4500 4WD 32 SPL 51 0205 5 32 GM 4L60E 4W D TRANS 50 0405 amp E 27 12 375 CASE LENGTH 51 0220 W REMOVABLE BELLHOUSING 5 9 1 1 1 DODGE NV4500 4W D 23 SPL STOCK 5 7 23 GM 4L60E 4W D TRANS sHorty 50 9300 3 23 12 375 CASE LENGTH 6 3 ADAPTER W REMOVABLE BELLHOUSING 50 9305 3j DODGE NV4500 4W D 29 SPL STOCK 5 7 29 GM 6L80 6L90 50 9600 32 or 29 6 3 ADAPTER
8. Dodge tailhousing 23 spline transmissions retain the stock seal in this housing 29 spline transmissions require this seal to be removed GM NV4500 4WD Requires 1 51 0205 Adapter hsg 8 720028 1 51 0220 1 625 spacer 6 723766 ATA GM 4L80E 4WD Requires 1 AS 6408 Adapter housing 1 50 6409 or 50 6410 1 625 Reluctor kit 6 720028 GM 203 REDUCTION BOX If you re looking for the ultimate low gear option we offer an adapter that couples a NP203 reduction box in front of the Atlas transfer case This NP203 must be coupled to a TH350 700R 4 TH400 or SM465 Transfer case linkage crossmember and floorboard modifications are necessary P N 50 8810 couples the Atlas to this NP203 reduction box The input of the Atlas must be equipped with a 10 spline shaft The length of the NP203 and adapter to the Atlas is 10 0 long ATLAS FRONT INPUT SHAFT The Atlas is designed to fit numerous types of transmissions The multitude of Atlas inputs are designed to fit to various stock transmission output shaft splines Depending on the transmission of your choice the Atlas can be bolted to the transmission using either a stock adapter or one of our transfer case adapter housings When using a transmission out of a 2WD vehicle or even with some 4WD transmissions you may be required to install a complete adapter kit which would include a new output shaft This requirement is due to eith
9. PLCS EQ SP 24 250 B C ES ac re lt 4 uc a YOKE LENGTHS AND U JOINTS 2 28 SPEEDOMETER OPTIONS The Atlas long tailhousing is the only housing that offers a speedometer option sold separately The Atlas long tailhousing is designed to fit a stock Jeep 1982 amp up mechanical driven speedometer housing These housings generate a pulse that operates the speedometer Vehicles requiring a cable connection for the speedometer can order P N 301506 as part of the Atlas order This speedometer housing is from a 1983 to 1986 Jeep CJ The speedometer gear is not included with this housing but by using the charts that follow you can select the correct gear for your tire size and axle ratio Some of these gears are hard to come by so we may not offer the gear for your application If your stock cable does not fit this speedometer housing or if you require additional speedometer connections then we recommend that you contact Nevada Speedometer at 775 358 7422 P N 301506 Speedometer housing P N 300630 Replacement seal and O ring If a long tailhousing is needed but you do not want a speedometer we also offer a plug for the tailhousing If your application does not require any speedometer connections order P N 300621 speedometer hole plug The late model Jeep TJs with the Rock Trac 241J transfer case used a tone ring and sensor for the speedometer pickup source This combination is not able to be used on the Atlas t
10. The is the length Atlas 4 Right Drop A427R peru ue TH350 4WD When obtaining a TH350 out of a 4WD vehicle the output shaft will protrude approximately 1 from the rear square flange of the transmission An adapter housing P N AS 6800 can be purchased from us to use this transmission with this stock 27 spline 4WD output shaft TH350 ZWD When obtaining a TH350 out a 2WD vehicle be aware that there are three different stickout lengths 6 9 amp 12 inches These transmissions would be better suited to either switch to a 4WD TH350 output shaft and use the adapter housing listed above or use P N 50 6300 3 6 long or 50 6802 1 5 long Both of these kits require the installation of a new output shaft which switches the output spline to a 23 spline See the 23 Spline section POWERGLIDE The Powerglide automatic transmission has gained popularity in rock crawling vehicles We offer a new cast aluminum adapter and crossmember mount designed to couple the Powerglide to the Atlas transfer case Part No 50 9200 The adapter kit requires a shorty 27 spline output shaft to be use when coupling the Powerglide to the Atlas Two sources to obtain this shaft would be Hughes Performance or B amp M 7OOR amp 4L60 4WD When obtaining a 700R or 4L60 out of a 4WD vehicle the output shaft should have a stickout length of 2 75 from the rear square flange of the trans mission Adapter housing P N AS 9111 2 5 long can be purchased f
11. and 50 9421 6L90 4WD 6 speed automatic is also a 29 spline transmission This transmission can be used with our 50 9600 kit The VSS tailhousing option would provide the GM computer the speedometer signal for this application Dodge amp GM Inputs Since all of these transmissions are used in larger vehicle applications we have had requests for upgrade options on the Atlas One limited upgrade offered for these transmissions is the heavy duty Atlas input 300M This was developed for some applications that had an increase in horsepower and needed extra strength The heavy duty input is not needed for all applications but it s available if you feel you ll need it 29 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop 125 Stickout length is the Atlas 2 Heavy Duty Input length that the shat protrudes from the rear o Left at Right Drop 125 the transmision with the adapter installed The Atlas 4 Left Drop 500 length thatthe Afias wil Atlas 4 Right Drop 500 accept T STICK OUT MAX 29 gt SPLINE DODGE NV4500 gt EZ WY mis SPORE 7 A eet eer FRONT INPUT SHAFTS FORD 25 SPLINE The 25 spline Atlas was designed to fit only the Bronco IIs Ford Rangers and coupled to a Borg Warner 1350 transfer case The bolt pattern on the face of the B W 1350 is a 5 bolt pattern which we mirror on the Atlas transfer case Fitting an
12. arm kit the Atlas 6 4 Speed will not fit these vehicles with this suspension installed RATIO OPTIONS CUSTOM BUILD YOUR ATLAS 2 SPEED TRANSFER CASE 1 GEAR RATIO PAGE 6 ATLAS20 ATLAS30 ATLAS38 7 YOKE OPTIONS list rear output 1st PAGES 26 27 NUSE SENE o wm Gv _ ATLAS50 A1310 32 SPLINE YOKE non C V 2 INPUT SPLINE T E A1310CV 32 SPLINE YOKE 32 SPLINE YOKE GM 10 SPLINE o 32 SPLINE YOKE non C V A21 JEEP 21 SPLINE A1350CV 32 SPLINE YOKE 3 2 INPUT STICKOUT Suai ONG INET MAL Desc aE A23SHORT JEEP 42RLE TRANS JK S amp 2012 MANUALS non cv u bolt style A234L60 SHORT 4L60E INPUT 23 SPL KU o RN UNE a E 5 BRONCO II HAS A LEFT DROP T C 6 2012 JK AUTO TRANS 8 SPEEDOMETER OPTIONS PAGE 28 30 7 GM 27 SPLINE 301506 MECH SPEEDOMETER HOUSING 8 ORD Ze PHAP 300621 SPEEDOMETER HOLE PLUG A28C4 C4 TRANSMISSION 9 DODGE 29 SPLINE 300640 ES EEE c LT A29HD DODGE 29 SPLINE HD MATL Does not include the speedometer drive gear See Page 31 FORD 31 SPLINE ir NE Lem A32HD GM 32 SPLINE HD MATL 303001R UNIVERSAL RIGHT a 303002L TJAUTOMATIC A32NT NISSAN TITAN 32 SPLINE LEFT DROP T C 303002U TJUNIVERSAL oe 303003L TJ MANUAL AD32 DIVORCED UNIT REQ EXTRA YOKE 303004L BRONCO Must have a VSS tailhousing or a TruPulse kit 303005L 3 CASE ROTATION OPTIONS 303006L EXPLORER PAGES 22 23 303007L x 303008 JKSHIFTER 303009 UNIVERSALCABLE A Divorced Atlas
13. ground with the brakes applied and the transfer case in low you will notice deeper squat in the suspension as you shift your automatic transmission into gear If you have large disk brakes front and rear you will be well equipped to control the increase in torque If you have drum brakes or a set of stock vehicle brakes front and rear you might find it hard to stop the vehicle when the transfer case is in its low range gear There are many aftermarket brake upgrade kits out on the market For serious off roading this upgrade should be considered Differentials You are sure to find your weakest link lf you are not sure about the capacity of your current equipment you may want to consult with an expert in this field Research any 4WD magazine for the various sources of manufacturers and distributors TOWING The ATLAS 2 speed has been flat towed for a distance of 300 miles and no problems were encountered At this time we can only recommend flat towing at this maximum distance After 300 miles of travel the vehicle should be started With the transmission in gear and the Atlas in neutral let the vehicle idle for 5 10 minutes This will circulate the oil in the Atlas and allow for proper lubrication We recommend that the Atlas should have at least 500 driving miles on it before you flat tow allowing the bearings to break in When a vehicle is being towed with the Atlas 2 speed both shift levers should be in the Neutral position Our expe
14. is not an issue We use a planetary assembly that was originally run in a NP241 HD transfer case The six planetary setup has proven its durability and has been used in countless heavy duty vehicles Other attributes to the planetary assembly include a very quiet operation easy shifting and low rolling resistance When all of this is put in front of a legendary Atlas Transfer Case you get the best combination of gear ratios and reliability The 4SP units will fit nearly all transmission applications that the standard Atlas will bolt to These will include spline counts of 21 23 27 29 31 32 and 34 The unit has a circular 6 bolt pattern on the front identical to the one found in Jeep vehicles We have a variety of different adapters available to retrofit the 4SP into nearly any application The twin sticks for the main unit can be either the standard linkage or the cable linkage The standard link age is offered in a variety of custom packages available for particular vehicles and can be modified to fit many custom applications The installation of an Atlas 4 speed should be nearly the same as the standard Atlas 2 speed The Atlas 4 speed is just a bit longer We do not recommend flat towing vehicles equipped with the 4 speed due to the additional bearings used in the planetary housing ATLAS 2 AND 4 SPEED DESCRIPTION ATLAS RATIO SELECTION The Advance Adapters Atlas gear driven transfer cases are the ultimate in gearing and strength
15. must use a standard 6 N gt gt gt 4 SHIFT CONTROL OPTIONS PAGE 32 301510 LEFT SHIFTER CONTROL 301511 RIGHT SHIFTER CONTROL 5 TAILHOUSING OPTIONS PAGE 24 25 The Atlas 2 speed left in comparison to the NP231 right with a fixed yoke kit 6 FRONT OUTPUT SHAFT OPTIONS PAGE 25 AF 26 26 SPLINE FRONT OUTPUT AF32 32 SPLINE FRONT OUTPUT 7 CUSTOM BUILD 2 SPEED CHART CUSTOM BUILD YOUR ATLAS 4 SPEED TRANSFER CASE 1 GEAR RATIO PAGE 6 ATLAS4 20 1 1 29 1 2 72 1 7 5444 PAGES 32 33 ATLAS4 30 1 1 2 72 1 3 0 1 8 16 1 9 SHIFTER OPTIONS SOLD W ATLAS ATLAS4 38 1 1 2 72 1 3 8 1 10 34 1 344000 UNIVERSAL RIGHT or LEFT ATLAS4 43 1 1 2 72 1 4 3 1 11 7051 344002 TJAUTOMATIC 344003 TJ MANUAL 344004 BRONCO LEFT DROP RIGHT DROP 344005 4211 A4218 iuo EXPLORER BRONCO Il A423L A423R Co 7 A423LLONG LONG23 SPLINE 344008 A423L SHORT JEEP 42RLE TRANS JKs 303009 4 UNIVERSAL CABLE 27 MIR 3080204 CABLE SHIFTER 2 INPUT SPLINE amp CASE CONFIGURATION PAGES 11 21 A4291 MER 0 y A431L A431R 10 REDUCTION HOUSING SHIFTER A432L A432R 1 L944020 CABLE SHIFT REDUCTION BOX A434L A434R FORD 34 SPL TTT Note The Atlas 4 speed will not work in 2012 and newer 3 CASE OPTIONS PAGES 22 23 JKs with the auto transmission 305100 LEFT DROP due to computer programming _ 305101 6 9800 So RIGHT DROP issues The Atlas 2 speed is 4
16. needed the speedometer access hole can be plugged by using P N 300621 Atlas Short Tailhousing No Speedometer Since rock crawling events have become steadily amp increasingly popular so have the requests for additional Atlas upgrades The rock crawling industry has ventured into shorter drivetrains and light weight rear engines combina tions With these newer combinations we were prompted to build a shorter Atlas tailhousing This tailhousing is 2 shorter than the standard Atlas tailhousing It is designed for trail or competition use only since it does not provide provisions for any type of speedometer This new tailhousing can be retrofitted to any Atlas case by ordering P N 301499R If you re ordering a new case this item can be included on a new Atlas 2 speed by using P N AST32 Not recommended for street use HD Atlas Tailhousings with 300M Output Shaft The HD Atlas rear tailhousing is basically the same as the standard and short housing with the exception on the output shaft The output shafts in these tailhousings are manufactured out of 300M steel This was introduced into our product line for a special aftermarket military vehicle This high grade steel shaft is 130 stronger than our standard output This kit is not necessary for most applications however for extreme horsepower and torque this Atlas HD tailhousing may be for you The HD tailhousing is available for the all new design 4 speeds and available for all the Atl
17. online at www advanceadapters com NG Some additional components will be required when changing input shafts Parts required to change out to a new front input Atlas 2 Speed 1 300499 Input seal for 29 31 32 34 amp 35 splined input shafts 1 300500 Input seal for 10 21 23 25 27 amp 28 splined input shafts 1 716453 Snap ring 1 300490 O ring for input ring 6 723730 Frontretainer bolts 1 300510 Sealed bearing 1 301400 Access cover gasket 2 300358 Cluster pin o rings 1 716455 Snapring The input shafts have undergone one change over the years which was the internal spline of the drive gear that fastens to the shaft The splines that have been used are a 6 spline and a 32 spline We have made it fairly simple to identify which application you have by adding a G to the four digit serial number of each case that has the 32 spline drive gear requirements In 2009 we switched to a 6 digit number machined into the case these cases do not have a G on them but they are the 32 spline input to gear applications Atlas 2 speed inputs Add an A at the end of these numbers if your Atlas serial number has a G at the beginning or is a 6 digit serial number We have stopped manufacturing some of the 6 spline inputs please call to check availabil ity if doing a input change on a early transfer case 300012 Long 23 spline input 300112 23 spline input 300117 27 spline input 300013 Short 23 splin
18. pues fedem ai i EE NW X ADAPTER CASTING AA P N 51 9807 JEEP MOUNTING AREA strength features to vehicles that require a remote mounted transfer case Early vehicles sometimes ran this type inde pendent transfer case It was attached to the powertrain by a small drive shaft coming from the transmission This transfer case functioned identical to others and had a front and rear driveshaft The entire transfer case assembly was hung from the frame on a crossmember type mount The Divorced Atlas can be built as either a right or left drop unit The shifters and crossmember are sold as a separate kit to fit the transfer case When ordering yokes for this unit 3 are required The mount plate included in our kit will give you the rigid mounting location for supporting this gear box to the frame Prothane bushings and all hardware are included in this kit It is necessary that you fabricate a support bracket from our transfer case mount to the frame rails of your vehicle Please be aware that this new mount bracket is very rigid and should be able to withstand the extreme twisting load that the gearing of the Atlas transfer case creates Keep in mind that a good amount of frame flex may be generated in severe offroading conditions We only offer the divorced units in the 2 speed configuration Atlas 2 Speed P N AD32 Left Drop Case Mount and Cable Shifters P N 303025L Right Drop Case Mount and Cable Shifters P N 303026R A
19. supported securely Recommended Equipment A floor jack to support the tranny and engine when the crossmember is removed and a transmission jack for raising and lowering the transfer cases The Advance Adapters Uni Raise shown left P N 15 1000 a helpful tool when doing drivetrain work By unbolting and removing your stock transfer case you should have your transfer case adapter and output shaft exposed The adapter housing transfer case mating flange should be cleaned of any debris Double check the output shaft splines of your transmission and verify the stickout length Make sure the Atlas has the same spline and that the length of the transmission outputisn ttoo long for the Atlas input Refer to the Atlas Input Shaft section for more information The Atlas should now be test fitted into the vehicle The Atlas should index onto the spline of your transmission and up to the adapter housing While holding the Atlas securely in place rotate the transfer case to the desired rotation for your vehicle Locate a stock hole on the adapter housing Using a marker mark the outside of the Atlas index ring This will help to identify the rotation pattern Check for tunnel clearance front driveshaft clearance and shifter clearance with the Atlas in this new rotation Note On many of the YJ TJ and CJ vehicles a minor modification to the tunnel area will allow you to mount the Atlas at a higher rotation with little or no crossmember modifi
20. the harder it is to stop the vehicle when in gear Larger brakes will be required to slow the vehicle Shifting the transmission into neutral on an automatic or depressing the clutch on a manual will be required to bring your vehicle to a complete stop Atlas 2 Speed Ratios 2 0271 This unit is more of a stock ratio found in most early full size trucks and used in quite a few competition rigs 3 0 1 This unit is popular in numerous applications Used in quite a few competition rigs 3 8 1 TheAtlas 3 8 is a good choice for the avid 4 wheeler since this low gear ratio is ideal for moderate to some extreme rock crawling 4 321 This unitis popular in numerous applications 5 0 1 This unit is popular in numerous applications Atlas 4 Speed Ratios 1 0 1 2 00 1 2 72 1 5 44 1 1 0 1 2 72 1 3 00 1 8 16 1 1 0 1 2 72 1 3 80 1 10 34 1 1 0 112 72 114 30 1111 70 1 With any of the Atlas ratios equipped in your 4WD you have the opportunity to select a sensible ring and pinion gear ratio for great street performance Combined with a low geared crawl ratio of your choice your vehicle will have the ultimate combi nation This allows you to compete with the most well equipped vehicle but then be able to cruise comfortably down paved roads If you are serious about on and offroad performance ARP and dependability then demand one of the Advance Adapters vaz Atlas transfer cases Note On Jeep TJs with a Nth Degree long
21. trucks The choice between the two splines can also be affected by your driving habits The 26 spline shaft in a stock vehicle can break if the vehicle is abused or power is applied while the tires are bound up while offroading The 26 spline shaft kit is an option in the Atlas 2 speeds only with gear ratios 2 0 3 0 3 8 amp 4 3 The Atlas 5 0 and Atlas 4 speeds come standard with 32 spline front output 26 Spline Front Output Shaft Kit AF26 32 Spline Front Output Shaft Kit AF32 We also offer a kit to retrofit an Atlas from a 26 spline to a 32 spline front output This upgrade kit can also be installed into any previously built Atlas Instructions are provided online for mechanically inclined individuals to perform this upgrade 32 Spline Upgrade Kits for used Atlas Units ARF32 32 spline front output Yoke is sold separately FRONT YOKE OPTIONS YOKE OPTIONS AND INTERCHANGEABLE YOKES With the Atlas transfer case being such a diverse case fitting into such a wide variety of vehicles naturally we needed a variety of available transfer case yokes The yokes we offer are for the 26 spline front output shaft and the 32 spline front and rear outputs shafts The yokes that follow are listed in 3 different ways ist column is when ordering a new Atlas 2nd column is when you re ordering a replacement yoke for an Atlas which would include a new seal seal washer and nut and the 3rd column is just the yoke by itself The last two column
22. updated information and complete package pricing The Atlas should be equipped with a STD 23 spline input FRONT INPUT SHAFTS GM 32 SPLINE TH400 The 32 spline Atlas was primarily designed for the GM TH400 transmission with a 32 spline output shaft One of the biggest problems with the TH400 transmission is that it was used in numerous vehicles which required numerous output shaft lengths We estimate there are 7 different output lengths that the TH400 has been equipped with over the years in both 2WD and 4WD applications We cannot fit all of the stock output shaft lengths however the Adapter Selection Charts on Pages 9 amp 10 will assist you with the adapters we do offer If you do not find an adapter housing to fit the output shaft you have you may be required to change out the output shaft or use one of the different spacer adapters to fit your shaft length 4L80E This transmission was designed by GM to replace the GM TH400 transmission Like the TH400 the 4L80E has a 32 spline output shaft The major difference of the 4L80E is that the transmission index diameter is different than the TH400 We have seen 5 different output shaft lengths that were used in the 4L80E transmission The Selection Charts on Pages 9 amp 10 list the adapter plates that would be used only with the 4WD 4L80E transmission If you have a 4L80E that has a longer output shaft stickout and the length matches an adapter we have listed under the TH400 section we can
23. 00 Toyota Tacoma 1995 amp 1 2 to 2004 with both the automatic and manual transmission and a 4 cylinder or the V6 can now have an Atlas 2 speed transfer case installed This also includes the Tundra 2000 to 2004 V6 amp V8 or the T100 We use a 3 8 adapter plate that couples the Atlas to your transmission We offer the Atlas in either a left or right drop left being for stock installations The Toyota transmission either had a 23 spline or 26 spline stock output shaft Our spud shafts couple to either one of these splines and then provides a Jeep 23 spline output The Atlas would need to be ordered with the following input Note On Tacomas the speedometer output must be verified as to whether it is needed or not Atlas 2 Speed P N A23 NISSAN Titan Frontier Xterra The Nissan Titan Frontier and Xterra are applications suitable for the Atlas transfer case The Atlas fits the automatic transmission and couples directly to the Nissan output shaft We manufacture a new input shaft for the Atlas to couple to the Nissan transmission output shaft The Nissan transmission requires an adapter plate to bolt on the Atlas Part No 50 1114 The Atlas 2 speed transfer case is the only configuration for Nissans A complete detailed installation for the Nissan Xterra or Frontier can be found online at www advanceadapters com Left Side Front Driveshaft Atlas 2 Speed P N A32NT NISSAN Hard Body Pathtinders The Nissan Hard body and Pathfinders wer
24. 5 Right Universal Atlas shifter P N 303007LA XJ AW4 Atlas shifter P N 303002LA TJ Automatic Atlas shifter P N 5030081 JK shifter P N 303002UA TJ Universal Atlas shifter P N 303009A Cable shifter P N 303003LA TJ AX15 Atlas shifter P N 303020A Cable shifter P N 303004LA Bronco Atlas shifter ejN P N 303005LA ZJ 6 Left Atlas shifter ny DIVORCED ATLAS SHIFTER amp SUPPORT P N 303025L Left drop Divorced case shifter and support mount P N 303026R Right drop Divorced case shifter and support mount Atlas Shifter Linkage Upgrade The connection rods for the Atlas were designed to be universal so they could be adjusted for the various drivetrain lengths The stock linkage works well for the majority of applications and vehicles The extreme racers and rock crawlers on the other hand were looking for a linkage that would withstand the abuse that they are putting their rigs through The two kits offered are upgrades that work with the standard handles and use heim joints that are bolted to the Atlas linkage Anyone can upgrade to these kits as they will work on all Atlas ridged mounted twin stick applications P N 303040 or P N 303041 View the application details amp descriptions online 2 SPEED SHIFTER OPTIONS 3l 32 ATLAS SHIFTER CONTROLS The Atlas is used in a wide variety of applications We are seeing more rear engine applications now than ever before One problem with a rear engine application is that the r
25. 50 5040 with a 1310 non C V P N 50 5041 with a 1310 C V P N 50 5042 with a 1350 non C V P N 50 5043 with a 1410 non C V FRONT OUTPUT OPTIONS The Atlas 2 speed was originally designed with a 26 spline front output shaft As the Atlas gained popularity and a rock solid reputation for strength the owners of rigs with high horse powered engines long wheelbase larger tires and ve hicles with higher G V W ratings began requesting this transfer case for offroad performance and reliability A longer wheelbase or higher G V W vehicle classification simply means less weight transfer toward the rear of the vehicle under operating load therefore more strength demand is put upon the front output shaft The large tires and higher horse powered engines also put more stress on the front output shaft when in 4WD A larger 32 spline front output shaft capable of handling higher load ratings is the solution We now require you to specify the spline count of your Atlas transfer case either a 26 spline or 32 spline front output shaft The 26 spline was designed for ve hicles with stock engines a G V W of 5 000 lbs and up to a 35 tire size The 32 spline front output should be used if your vehicle requirements exceed this rule of thumb listed above The larger 32 spline shaft will accept larger and stronger front The 32 spline upgrade can be identified o DD E S yoke assemblies commonly found in larger class vehicles half ton to one ton
26. 600 SF Gear sets introduced for the off road racers Changed breather location and venting design on the main case 10143 Increased tap depth of pan mounting threads from 45 to 75 min depth on case and went to longer Atlas pan bolts 10289 Changed from 5 16 75 B H C S to 5 16 1 B H C S on the pan bolts 10500 Changed from 5 16 1 B H C S to 5 16 1 F H C S flange head cap screw Grade 5 to aid in assembly 10550 The second generation Atlas 4 speed was released The Atlas front retainer for the 32 spline front output is now a one piece housing Added spot face feature to rear bearing cap and changed bolts to 5 16 1 F H C S 10875 Added Advance Adapters to the engraving on the main case 10910 Removed pockets from cluster pin bore so that cluster pin could be lengthened 12314 old pin P N 300122 new P N 3001224 Changed 300384 casting to allow for all 1 25 mounting bolts 12299 All Atlas shipped with solid synchro dogs vs the sheet metal ones Cable shifter connections at the transfer case are easier to install and allows removal without disassembly of the shifter box Less chance to break a cable due to installation error Atlas rearshift block is machined the same for all Atlas cases and the shift rails are now bio directional Atlas 4 speed planetary has been revised to allow all inputs to fit into one housing Atlas 3 0 Gears are now all full fillet design These gears should not be
27. Atlas into these vehicles will require either a body lift such as the Daystar mounts we offer on Page 4 or modifications to the stock crossmember The rotation of the Atlas is identical to stock The Atlas 2 speed is the only unit available for these transmissions 77 Explorers The stock transmissions used in these vehicles were normally FORD 25 SPLINE YL 44 SST Atlas 2 Speed P N A25 Photo of a stock Ford tailhousing All Ford V6 Explorers Rangers and Bronco lls have the same bolt pattern and splines when coupled to a 1350 transfer case The adapters we manufacture for these vehicles to fit the C4 and AOD would also have this same pattern FORD 28 SPLINE amp 0 350 STICK QUT MAX AL e 5 KC 2 EN 77 HAAN 99 1 The 28 spline Atlas was designed to fit only the 1966 77 Broncos The stock transmissions used in these vehicles were normally coupled to a Dana 20 transfer case The bolt pattern on the face of the Dana 20 is a 6 bolt hex pattern which we mirror on the Atlas transfer case The rotation options of the Atlas into these vehicles are 42 degrees which is stock 35 degrees for additional ground clearance and 28 degrees requires some internal frame modifications NOTE When bolting the Atlas up to an automatic C4 transmission we offer a shorter Atlas input shaft to avoid spline run out When using a NP435 or T18 transmission with one of our adapter housings the threaded portio
28. By Advance Adapters Inc Performance Transfer Cases RUBI SRAWLER t a j f BOOKLET NO ATOI3 MARCH 1 2013 805 238 7000 Nationwide ADVANCE ADAI2TEPS Arn LN P O BOX 247 93447 4320 Aerotech Center Way 805 238 4201 Fax PASO ROBLES CA 93446 800 350 2223 Toll Free U S only www advanceadapters com his tec edition ofthe Advance Adapters Atlas manual has been prepared to assist you in the general information regarding the Atlas transfer case as well as installation recommendations An Atlas Transfer Case is sure to change the way your vehicle performs off road You will benefit greatly by understanding the Atlas characteristics and how to apply them forthe ultimate in trail performance If you should have any questions or comments please feel free to contact our sales staff The information in this guide is constantly being updated and we ask that you verify any information that may be critical to your application Please REREAD the OPERATING INSTRUCTIONS once youhave completed yourinstallation TABLE OF CONTENTS General Information Nissan Hard Body PathHBOEEs usos eed este aeter etat 21 SBCCHICICIDIS s dst ESI E PS MR CMS 3 FECHESEE eoi tte aisi O 21 Atlas Information amp Accessories 4 OE Military amp Special Applications 2o epo tpe 21 Atlas 2 amp 4 Speed Description amp Ratios Options 5 6 Atlas Rotation Options
29. E SWITCHES 2 SPEED SHIFTER OPTIONS We have designed several different shifters to fit various vehicle applications If your specific vehicle application is not listed a universal right or left hand shifter should be used Areas of consideration on any installation are vehicle console and floorboard clearances These shifters have been designed mainly around stock vehicles Vehicles with body lifts greater than 1 may require more than the usual modifications for proper fit of the shift handles All twin stick shifters with the exception of the cable shifter are included at no additional cost when an Atlas is purchased SHIFTER SOLD WITH AN ATLAS P N 303000L 5 5 Left Universal Atlas shifter P N 303005L ZJ 6 Left Atlas shifter P N 303001R 5 5 Right Universal Atlas shifter P N 303006L Explorer Bronco II shifter P N 303002L TJ Automatic Atlas shifter P N 303007L XJ AWA Atlas shifter P N 303002U TJ Universal Atlas shifter P N 303008L JK shifter additional cost P N 303003L TJ AX15 Atlas shifter P N 303009 Cable shifter additional cost P N 303004L Bronco Atlas shifter P N 303020 TJ Cable shifter additional cost NOTES 1 The Lokar auto transmission shifters may have some clearance issues with the Atlas cable shifters 2 The Allison transmission coupled to the Atlas 2 speed cannot use cable shifters A ATLAS SHIFTER SOLD SEPARATELY P N 303000LA 5 5 Left Universal Atlas shifter P N 303006LA Explorer Bronco II shifter P N 303001RA 5
30. K SIDE OF THE ADAPTER HOUSING ADAPTER SELECTION CHART 10 A RELUCTOR RING AND SENSOR KIT MUST BE PURCHASED P N 716073 M465 Adapter Parts Required 1 51 9807 Adapter Housing 1 716515 A SM465 Gasket is 7 723723 3 8 H H C S 1 723711 3 8 Stud Bolt 8 723704 3 8 Lock Washer 1 723701 3 8 16 Nut In addition the 35 spline M465 Requires 1 716457 Set Collar P N AS 6401 Includes a 1 25 adapter a gasket and 6 standard socket head cap f Screws 4 25 TH400 ADAPTER HOUSING 1 51 6400 Adapter Housing 1 716510 Gasket 6 723723 3 8 16 x 1 1 2 H H C S 6 723704 3 8 Lockwashers ALLISON amp GM ZF 6 650 TRANSMISSION When coupling to these transmission a special drilled CHEVY case is required When coupled to the Allison transmission the shifters for the Atlas will require some modifications Cable shifters cannot be used with the Allison tranmission P N AS 0404 Includes a 1 spacer adapter 6 longer studs 6 lockwashers and 6 nuts P N AS 8603 Includes a 3 4 spacer adapter and 6 bolts P N AS 8610 Includes a 1 2 spacer adapter 6 longer studs 6 lockwashers and 6 nuts ADAPTER SELECTIONS P N AS 6800 Includes a 1 5 adapter an o ring 4 metric and 4 standard socket head cap screws P N AS 9111 Includes a 2 5 adapter an o ring 4 metric and 4 standard hex head cap screws adapter not shown Dodge NV4500 4WD Requires A stock
31. N H standard labeled P N 303150AA 2 75 L N H standard labeled P N 303152 2 75 H N L reversed labeled P N 303152AA 2 75 H N L reversed labeled Body Mounts When installing an Atlas in some vehicles floorboard clearance can become an issue We now offer Daystar s Comfort Ride body lifts for most applications The Jeep TJs and Y Js can be installed with in Atlas without a lift but the extra 1 provided for these vehicles aids in the installation process DA P N 714450 TJ or P N 714452 YJ COAT eS DE ATLAS INFORMATION AND ACCESSORIES ATLAS 2 SPEED DESCRIPTION Through the analysis of other successful transfer case designs we have manufactured a rugged all gear driven transfer case Combining the latest in CAD CAM technology and years of in house CNC machining capabilities the Atlas transfer case is sure to bring you the utmost in dependability and performance The Atlas is available for both left and right hand vehicle applications with centered rear differentials The solid one piece case design is manufactured from 356 T6 heat treated aluminum alloy This material is also used for the structural access cover and all other exterior components The massive gears are helical cut and synchro equipped for quiet performance and shift on the fly capability These gears are supported by needle bearing elements precision matched to strong 8620 shafts The ruggedly designed output shafts are amply supported by tape
32. ON This unit is shipped DRY Before operating your Atlas please fill with the recommended gear lubricant Amsoil MTG GL 4 Torco MTF GL 4 or any other A P I GL 4 rated synthetic gear oil If you are unable to find these lubricants one of the following synthetic oils can be substituted as a temporary fix until the proper fluid can be obtained Castrol Syntec 5w 50 or Mobil 1 Synthetic 15w 50 The recommended oil capacity is 2 quarts in the Atlas 2 soeed and 2 1 2 quarts for the Atlas 4 speed transfer case The Atlas does not offer any type of weep hole to verify the oil level Therefore we have supplied your unit with a site tube to aid in determining the correct fluid level Once the required two quarts are put into the Atlas we recommend marking the oil level on the site tube We like to use a small zip tie as a oil level marking device Note When the Atlas is overfilled beyond the recommended levels it will cause the unit to vent the extra oil out the breather PREPARATION Now is a good time to familiarize yourself with the shifter components Pre assembly of the shifter items will help a great deal with the final installation Unpack the shifter and install the shifter base Use RTV Blue silicone to seal the bolt threads Pre assemble the rest of the components Detailed shifter assembly instructions can be found in The Final Installation section Once the shifter has been properly setup remove it from the transfer case lea
33. SHIFT CONTROL OPTIONS the only option for these Jeeps 301510 LEFT DROP 301511 RIGHT DROP 5 TAILHOUSING OPTIONS PAGES 24 25 We stock several OE output shafts and have good sources to obtain others If you need a replacement shaft a EEL a to fit lication al its not listed AST32HD SHORT TAILHOUSING 300M Men y PP AVT32HD GM VSS TAILHOUSING 300M eh teas 6 FRONT OUTPUT Shafts that we stock AF32 32 SPLINE FRONT OUTPUT NV4500 4WD 29spl P N 52 0206 7 YOKE OPTIONS list rear output 1st PAGES 22 23 A1310 32 SPLINE YOKE non C V A1310CV 32 SPLINE YOKE See ae TH400 4WD 32spl P N 52 7001 A1350 32 SPLINE YOKE non C V 2 40 stickout length from trans A1350CV 32 SPLINE YOKE 65 00 A1410 32 SPLINE YOKE non C V strap style TH400 4WD 32spl P N 52 7002 A1410U 32 SPLINE YOKE non cv u bolt Yao stchsutlendibrmem Wane AF 1300 32 SPLINE FLANGE YOKE 1310 1350 AF 1410 32 SPLINE FLANGE YOKE TH350 4WD 27spl P N 52 1200 TOOR 4WD 27spl P N 52 7450 8 SPEEDOMETER OPTIONS PAGE 26 27 301506 MECH SPEEDOMETER HOUSING 300621 SPEEDOMETER HOLE PLUG 300640 ELEC SPEEDOMETER TJ 8 Does not include the soeedometer drive gear See Page 29 4L60E 4WD 27spl P N 52 7460 CUSTOM BUILD 4 SPEED CHART ATLAS ADAPTER SELECTION CHART The information listed below is to aid in the selection of the proper Atlas transfer case for the transmission you ve selected On certain transmission appl
34. TATION OPTIONS When coupling an Atlas to one of the various stock transmissions or to one of our adapter housings you will have a number of choices as to the degree of rotations The drawings that follow represent the stock Jeep and Advance Adapters tailhousing bolt patterns Once you have identified the bolt pattern on your adapter housing you can then select from the degree of rotation options listed along side your tailhousing bolt pattern These degree of rotations are approximate The rotation on your application may vary 1 to 2 degrees We also get quite a few requests for installing the Atlas at a zero degree or flat rotation We offer this option in both a right and left hand case application This option requires us to machine the case with a different bolt pattern for the Atlas input ring This case option should only be used if your goal is a flat rotation P N 301100LF Left drop Atlas 2sp flat rotation P N 301101RF Right drop Atlas 2sp flat rotation The Atlas 4 speed new design offers the flat or near flat rotation option on the standard case See the charts that follow for the 4 speed rotation options with the different tailhousings If a flat rotation case is not requested the Atlas is assembled with the standard case configuration The rotation options are as follows 1 j gN A 2 4 e wd lt a gt Got Be E Right Hand Drop Configuration Left Hand Drop Configuration OPTION 1
35. The Dodge NV4500 is probably the most popular Dodge transmission that we see coupled to the Atlas Most Dodge 4WD transmissions are equipped with a 23 spline output shaft The Dodge 4WD NV4500 1993 2000 has a 23 spline output shaft and has the correct tailhousing to bolt directly to the 23 spline Atlas transfer case Atlas 2 Speed Input shown Np KRA Dodge also has a heavy duty version of i Es the NV4500 transmission that was bolted 7 Ne up to a Cummins diesel engine This transmission along with the 2001 amp newer gas version NV4500 transmission was equipped with a 29 spline output shaft We offer an Atlas input spline for these heavy duty and late model transmissions See the 29 Spline section for more information m ROH I3 n GM amp DODGE 29 SPLINE Dodge NV4500 The 29 spline Atlas was designed to fit the 4WD Dodge heavy duty NV4500 transmission and the 2001 amp newer gas version NV4500 transmissions When coupling an Atlas to this transmission the stock Dodge 4WD tailhous ing can be retained The Dodge tailhousing bolt pattern is shown on the rotation Option 1 found on Page 22 When using an Atlas left hand drop transfer case the stock Dodge tailhousing requires the removal of the stock transfer case shifter bosses The removal of these two bosses provide the necessary Atlas shifter clearance NOTE The seal in this stock tailhousing must also be removed because it will
36. These units are the solution for combining both on and offroad performance From its inception in 1996 we have had numerous inquires to fit the Atlas into a wide spectrum of vehicles Today the Atlas has been installed in both full and down size vehicles such as Jeeps Broncos Explorers Dodge Chevy amp Ford Trucks These units can be found in daily driven vehicles all the way up to the extreme rock crawling vehicles When you want or need peace of mind on the trail in the rocks on the sand or in the mud the Atlas is the transfer case for you RATIO OPTIONS Since there are numerous engine transmission and axle combinations the need for various transfer case gearing options has increased The 2 speed Atlas transfer case now has 5 different low gearing options to suit the needs of your driving habits and your drivetrain components Along with the these different Atlas 2 speed ratio options we are now producing our new 4 speed Atlas transfer case The 4 speed Atlas gives you 3 low ranges amp 1 high range a few more choices when it comes to 4 wheeling You can now have the ultra low gearing for rock crawling alow range gear for trail use and mid range for sand and mud Whether you re looking at the 2 speed Atlas or the 4 speed Atlas your ratio options will be diverse The wide variety of Atlas gear ratio options have been designed to accommodate any type of drivetrain combination Please be aware that the lower the final drive ratio gets
37. ailhousing The Atlas only accepts the mechanically driven TJ Speedometer This NP231 style speedometer will work the same as the later model tone ring and sensor One advantage is the mechanical unit is easy to modify when larger tires or different ring and pinions are used The charts that follow offer different drive gear part numbers to calibrate your speedometer This speedometer assembly is offered under P N 300640 The speedometer gear is not included with this housing assembly SPEEDOMETER OPTIONS Fig F CHRYSLER SPEEDOMETER DRIVE PART NUMBERS TEETH COLOR 28T TEETH COLOR OLD JEEP P N 26T Part Number Parc Number 02067628 RED 52068148 52067630 30T 52068150 28T 02067632 32T BLACK 52068152 30T YELLOW J3212730 52067634 34T GREEN Discontinued 32T 77 492127132 52067636 36T RED 02068156 34T GREEN J3212734 52067638 38T BLUE 52068158 36T RED J3212736 52067640 40T ORANGE 52068062 40T ORANGE J3230222 52067642 42T WHITE 2538942 42T WHITE 53001489 The Chrysler part numbers listed above are becoming limited in supplies from the dealership We now carry these speedometer gears Some of these gears are standard Chrysler some are used recondition ones and some are imports The availability of all these gears is day to day If we do not have your required gear in stock we may not be able to provide an estimated delivery time Our aftermarket suppliers are working towards making most of these ge
38. alibrate the output shaft signal when in low range Note The Chevy computer may require some wiring and computer program changes for the different low ratios TAILHOUSING OPTIONS On Vehicles with computer controlled engine swaps this tailhousing kit can provide the proper VSS signal when using a manual transmission Vehicles with a computer controlled engine swap and an automatic transmission requiring a VSS should not use this tailhousing option unless a low range switch is installed and the computer program is modified When installing this type of engine and automatic transmission combination we highly recommend a reluctor ring location in the adapter or the transmission This will give the engine computer system a correct 1 to 1 reading in or out of low range The VSS tailhousing kit we offeris P N AVT32L If you have installed a newer GM engine into a Jeep with a manual transmission you may want to retain the Jeep speedometer but the GM engine needs the 40 pulse reluctor to function correctly The standard Atlas transfer case tailhousing should be retained and one of our TruPulse kits should be used These TruPulse reluctor kits fit on all of our Atlas tailhousings These kits are an externally mounted unit that provides the True 40 Pulse required for the computer system The reluctor ring gets mounted to the transfer case yoke The kit is offered in several yoke styles Note These kits will not work with a flange yoke TruPulse Kits P N
39. alling an Atlas Transfer Case A speedometer cable is used with a sensor housing to remote mount the VSS that was originally installed in the Toyota transfer case This kit is sold under P N 300605 You will also need the speedometer housing P N 301506 for the Atlas and the proper drive gear o_o O Low Range amp 4WD Switch A low range switch and pigtail is also available from us for the Atlas transfer case This switch P is from a stock Jeep TJ The switch can be used for an indicator light or a low range switch The sensor is P N 300378 Pigtail part number is P N 300378 C V PIN 300378 TJ Rubicon JK Jeeps Jeep TJs amp JKs In essence the Low Range switch tells the computer what mode the transfer case is in To operate the needed functions on these vehicles we only need one of four normal mode positions and that is the Low Range mode This mode allows the factory lockers and electric sway bar if equipped to work on the Rubicon series TJ JKs amp Power Wagons The other necessity is the ESP ELECTRONIC STABILITY PROGRAM in the JK series of Jeeps By installing the Low Range switch in the JK it will automatically turn the ESP to its lowest setting possible allowing front digs in low range tire slippage without engine hesitation or braking feedback It will also change the fly by wire throttle sensitivity to take away the side affects that usually consist of jerky throttle response that occurs as a result of runnin
40. ars as they become more scare from Chrysler Most of gears that we offer below are imported gears and may require a small modification On some of these gears the square hole on the shaft of the gear may be a snug fit to the speedometer cable If this is true in your application you may be required to sand or file on the square stock at the end of the speedometer cable to fit the gear However most of them fit fine and do not require this modification ADVANCE ADAPTERS SPEEDOMETER DRIVE PART NUMBERS SHORT GEARS LONG GEARS 300637 28 300637 36 300620 26 300620 34 300637 29 300637 37 300620 27 300620 35 300637 30 300637 38 300620 28 300620 36 300637 31 300637 39 300620 29 300620 39 300637 32 300637 40 300620 30 300620 40 300637 33 300637 41 300620 31 300620 41 300637 34 300637 42 300620 32 300620 42 300637 35 300637 43 300620 33 SPEEDOMETER CHART AND DRIVE GEARS 29 Toyota Speedometer Cable Adapter 1995 97 This cable adapter allows the Atlas speedometer drive housing P N 301506 to couple to the stock Toyota speedometer cable You can then retain the factory gauge and have all the added benefits of the Atlas transfer case This cable adapter is sold under P N 300613 and has a Toyota side 22mm w 203 female fitting and on the other end couples to the Atlas speedo housing side SAE 7 8 18 104 square Toyota Speed Sensor 1999 2004 FJ Cruisers T100 This kit allows you to retain the factory Toyota Vehicle Speed Sensor when inst
41. art numbers XLG is used for Extra large P N 716051B AA logo beanie black P N 716051B TBLOGO Throwback logo beanie black P N 716051HL LOGO Flexfit amp Large AA logo hat P N 716051HL LOGO FLAT Flexfit amp Large AA logo hat Flat Brim P N 716051 AA and Atlas logo T shirts indicate size D ANCEADAPTERS nc 4320 AEROTECH CENTER WAY PO BOX 247 PASO ROBLES CA 93446 Toll Free 1 800 350 2223 OR 805 238 7000 www advanceadapters com
42. as 2 speed at an additional cost P N ALT32HD or P N AST32HD GM VSS Tailhousing No Speedometer Vehicle speed sensors VSS are mandatory for computer controlled engines and transmissions The VSS sends information to the vehicle computer system for both engine and automatic transmission operations Early Chevys up to 1992 used a computer that required a D C square wave input into the computer These early computer system requirements could be fed by either a special speedometer drive or a reluctor ring Chevys 1993 amp newer required a A C sine wave This sine wave creates a voltage that increases with vehicle speed The only way that this voltage can be generated is through a reluctor ring mounted to either the transmission or transfer case shafts This information was obtained from various sources so please verify your requirements before doing any vehicle modifications Our tailhousing allows a sensor and reluctor to be installed in place of the speedometer drive Our Atlas tailhousing had to have some slight pattern changes to incorporate this new feature To add this option to an existing transfer case would require the purchase of a new tailhousing This new option was primarily developed so that the Atlas could be installed into a newer Chevy 4WD vehicle When ordering this tailhousing with an Atlas we also include a standard shift control unit that is drilled and tapped to accept a low range switch This allows the Chevy computer to re c
43. cations Refer to the specific vehicle application for more details at www advanceadapters com Once this is done remove the Atlas from the vehicle Locate the mark on the index ring of the Atlas transfer case The bolt patterns on the transfer case index ring are relative In other words whatever hole you ve selected will be the same all the way around the index ring Using the stud bolts provided install them in the chosen pattern rotation These studs are stock New Process items and are a restrictive fit into the front of the Atlas If you are using a spacer adapter that requires longer bolts or stud bolts they should be installed using 242 Loctite Install the studs so that they have full thread engagement in the transfer case adapter ring DO NOT PRELOAD THE STUDS INTO THE ATLAS INPUT RING TIP Before the final bolt up we have found it easier to equip the Atlas with all the necessary components For example Shift indicator switch speedometer site tube and drain plug etc The Atlas is also shipped with numerous red plastic caps to keep contaminates out of the unit At this point in time remove all caps and properly install all components INSTALLATION PROCEDURES THE FINAL INSTALLATION Apply a very thin film of RTV Blue silicone to your transfer case adapter mating surface Aligning the studs with the adapter holes and the transmission output shaft with the Atlas input the Atlas should slide completely onto the transmission mating s
44. e bellhousing To obtain the adapter length of only 600 we had to manufacture a new transmission output shaft This shaft is shorter than any other stock shaft made We mate this assembly with a custom Atlas 2 speed input ring which doubles as the adapter housing directly coupling the Atlas 2 speed to the 4L60E transmission The kit also includes a new crossmember support which bolts between the transmission and transfer case The overall transmission length will vary slight depending on the version of 4L60E transmission obtained This kit does require the VSS tailhousing option on the transfer case to work with the Compushift controller 1996 2000 Truck Gen II V8 6 315 bellhousing 22 336 O A L 2001 2006 Truck Gen III V8 6 945 bellhousing 22 966 O A L Compared to a TH350 w adapter of 23 000 or a 700R with our 50 9102 adapter at 24 875 This new kit uses a 23 spline output shaft made out of 300M material We sell the adapter in a kit or we also offer a complete transmission with our output shaft already installed Please call for complete package pricing SHORTY 4L60E ADAPTER w Removable for the ATLAS 4 Speed We also offer a shorty adapter for the Atlas 4 speed The adapter length of 1 625 is shorter than any of our other adapter options This new kit P N 50 9305 will use a 23 spline output shaft made out of 300M material We also offer a complete transmis sion with our output shaft already installed Please call for
45. e input 300113 29 spline input 300118 28 spl long input 300014 Nissan 32 spl input 300114 10 spline input 5001185 28 spl short input 300034 34 50 06 input 300115 31 spline input 300119 21 spline input 300111 35 spline input 300116 32 spline input 300120 25 spline input FRONT INPUT SHAFTS I 2 The input shafts for the Atlas 4 speed are late model stock New Process inputs gears These are the new gear pitch design from New Process f the wrong year input is used damage can occur to the planetary assembly The 4 speed case requires the disassembly of the planetary housing Instructions for this change can be sent to you or viewed online at www Advanceadapters com Parts required to change out to a new front input 1 305307 Input pocket bearing 1 305308 Input pocket bearing used on 29 amp 34 input gear only 1 305300 Input bearing except 31 amp 34 spline 1 340407 Snapring Atlas 4 speed inputs 305021 21 spline input 305023L Long 23 spline input 305032 32 spline input 50502355 Short 23 spline input 305027 27 spline input 305034 34 spline input 305023 23 spline input 305029 29 spline input 31 amp 34 spline inputs use a larger bearing and bearing retainer Switching to one of these input splines or from one of these spline to one of the other inputs listed above will require other components Please call for these parts amp prices JEEP 21 SPLINE The 21 spline Atlas wa
46. e it would normally be and use a washer under the bolt head to retain this part of the speedometer in place SHIFT INDICATOR The transfer case shift indicator if applicable should be connected Make sure wires and or hoses have proper body clearance and are not bound in any way For more information see the specific vehicles applications DRIVESHAFTS amp CROSSMEMBER SKID PAN You should now install your modified driveshafts Trial fit your crossmember or skid pan noting any modifications that may be necessary The Atlas is equipped with a drain plug located on the inspection cover You may wish to cut an access hole in your crossmember skid plate for easy access Once the modifications are made install the crossmember skid plate securely to the frame and the rubber support to the crossmember skid plate LUBRICATION Before lowering your vehicle fill your Atlas with the oil provided Amsoil MTG GL 4 Torco MTF GL 4 By using a hand pump connect the hose end to the upper fitting of the site tube to fill the Atlas to the recommended oil level Once this is completed re secure the upper site tube fitting to the Atlas If you are unable to find these lubricants locally we offer it under P N 303200 or one of the following synthetic oils can be temporarily substituted until the correct oil is found Castrol Syntec 5 0 or Mobil 1 Synthetic 15w 50 VISUAL INSPECTION Once the vehicle is back on the ground the transfer case area
47. e offered with two engine options a 4 or 6 cylinder engine The 4 cylinder had a transmission the was equipped with a 24 spline output shaft and the V6 had a 30 spline transmission output shaft We only offer an adapter to fit the 30 spline transmission to the Atlas transfer case This adapter is a three plate design with a spud shaft that requires the Atlas to be built with a Ford 31 spline input The adapter kit P N 50 1115 is 3 750 long to move the Atlas back far enough to clear the stock crossmember Currently the Atlas 2 speed is the only transfer case recommended for this application as the 4 speed Atlas would probably be too long of an assembly length This kit retains the stock transmission support The universal cable shifters would be the best option for this application Left Side Front Driveshaft Atlas 2 Speed P N A31NT FJ CRUISER amp Tacoma 6 speeds With all the hype on the new FJ Cruiser we knew it wouldn t be long before the requests came in for drivetrain swaps Although it does require a bit of modifying the option of both the Atlas 2 and 4 speed transfer case is now available to fit to the stock transmission Our adapter kit part number is 50 5715 manual trans and 50 5716 auto trans This kit comes with an adapter plate and spud shaft The shaft allows the FJ Cruiser transmission to bolt up to the Atlas 23 spline transfer case We recommend using a cable shifter due to the center console configuration in the FJ Cruise
48. e on these series NOTE If you replace the front 26 spline yoke with any of the yokes listed the nut that retains the yoke has a torque specification of 130 135 ft Ibs When replacing the front or rear 32 spline yoke with any of the yokes listed above the nut that retains the yoke has a torque specifications of 750 155 ft Ibs Front amp Rear Yokes for 32 Spline shafts 1330 series non C V Spicer P N 2 4 5521 amp C R 21164 U JOINTS Spicer D Dia E width Part Std Spicer series of cap in across caps in non C V U bolt Part 1310 1 062 5 153X 2 98 94X 1330 1 062 3 625 5 213X 3 94 58X 1350 1 188 3 625 5 178X 3 94 18X 1410 1 188 4 188 5 160X 3 94 18X 1480 1 375 4 188 5 188X 3 94 28X PARKING BRAKE OPTION We offer a parking brake kit that bolts to the rear tailhousing of the Atlas transfer case This unit is just the brake assembly only and not the handle or cable The kit comes with a new flange yoke for either the 1310 series yoke or the 1350 series yoke This kit provides the tail housing bracket for the caliper mounting It also includes the caliper flange yoke and support bar This parking brake is not intended to be used as an emergency brake and is not D O T approved Itis intended for offroad use only 5 2500 P N PM1500 1310seriesflange 7 16 20 THRU P N PM1501 1350 series flange Wc tors 61 9990 male index 1 2 20 THRU 4
49. e transfer case and measure the shaft lengths Refer back to this application guide to the input section for spline engagement lengths The Atlas is a precision built transfer case DO NOT FORCE TOGETHER even if it s a small gap between the transmission and transfer case The second most common mistake or problem is the cable shifter adjustments and installation We now offer several custom and universal cable shifters to fit the Atlas 2 and 4 speed transfer cases The instructions highly recommend installing the shifters to the Atlas while the transfer case is outside the vehicle This will allow you the opportunity to fine tune the linkage while viewing the movement of both the handle and the shift rail Adjustments to the linkage could be a half turn of a certain nut Ifthe Atlas amp shifters are installed that nut is hard to get a wrench on and you could spend a lot of time trying to get it adjusted correctly Incorrect adjustments to the linkage will make the Atlas hard to shift and we have seen some cables actually break because of driver trying to force a mis adjusted shifter The last area of concern 1s more of a precaution not an installation mistake After an Atlas was installed we have seen a couple of transfer cases that have experienced rear output shaft bearing failure The Timkin bearings require custom shimming for each Atlas built The tolerance is 001 which is the recommendation from Timkin The units we ve seen failure on have bee
50. e when the RubiCrawler Low is engaged P N 42R800 ADVANCE ADAPTERS INC LIMITED WARRANTY The RubiCrawler is guaranteed against defects in workmanship and materials for one year This warranty begins from the date the unit is shipped from Advance Adapters We log all units with a serial number at time of shipping The warranty is void as determined by Advance Adapters Inc by misuse abuse improper maintenance installation and or alterations to the product Warranty will be voided if the proper transmission fluid levels are not maintained if any transmission fluid other than ATF 4 is used or the product has not been properly installed and instructions have not been followed Do not disassemble or attempt to repair the RubiCrawler as doing so will void the warranty Please return the product as further described below These guarantees do not cover any outside labor shipping towing normal wear or any other unforeseen events that may occur due to failure of a unit Advance Adapters reserves the right to repair or replace any product All returns must have a returned goods authorization RGA prior to shipping the product and returns are to be sent prepaid freight 1 1 Please call 1 800 350 2223 and the sales department can assist you RUBICRAWLER INFORMATION The installation of a RubiCrawler into a Jeep is very simple and can be accomplished is a days time 8 hours on average The transfer case remains in the stock location so no driv
51. ear tailhousing of the Atlas is now facing the front of the vehicle When the Atlas is shifted in 2WD high the power is distributed to the front axle which makes the vehicle hard to control at higher speeds Our solution to this problem is to change the shifter control on the Atlas case This allows the Atlas to be shifted into 2WD high putting the power to the front output shaft of the Atlas which is connected to the rear axle You still have all of the same shifter options as you do with any stock Atlas case P N 301510 Left drop shifter fits right drop case P N 301511 Right drop shifter fits left drop case Atlas Shifter Knobs Option The Atlas twin stick shifter kit comes with two standard black knobs Make your Atlas installation look cool with these new billet aluminum or Black anodized aluminum knobs The Black anodized versions are designated by an AA at the end of the part number Knob sets come in two finishes P N 303150 and P N 303150AA are 2 3 4 tall The knobs are also available in a reversed shift pattern for certain cable shifter installations under and sold under P N 303152 or P N 303152AA All sets are priced at 42 95 4 SPEED SHIFTER OPTIONS MAIN CASE We have designed several different shifters to fit various vehicle applications If your specific vehicle application is not listed the universal shifter should be used Areas of consideration on any installation are vehicle console and floorboard clearances Th
52. ed shift design which means synchro sets have been added to SPEED MATCH the gear and shaft relationship If you are stopped with no forward motion and the unit will not shift place the transmission in Drive or Reverse then back to neutral then attempt to shift the Atlas DO NOT FORCE THE ATLAS INTO GEAR Shifting an Atlas with an Manual transmission While the vehicle is slowly moving forward depress the clutch and engage the front or rear control into Low DONOT FORCE THE ATLAS INTO GEAR or HOLD PRESSURE ON THE SHIFT LEVERS WHILE RELEASING THE CLUTCH As you become accustom to the operations of the Atlas and the unit accumulates miles the shifting will become easier TWIN STICK SHIFT POSITIONS Neutral Both the rear and front knobs in the N position 2WD High The rear knob in H position and the front knob in N position 4WD High The rear knob in H position and the front knob in H position 4WD Low The rear knob in L position and the front knob in L position 2WD Low Rear Drive ONLY The rear knob in L position and the front knob in N position Front Drive ONLY The rear knob in N position and the front knob in L position Special Note With the front in 2WD low the torque is distributed 100 to the front axle Combined with the low gearing in the transfer case these factors can cause undue strain on your front axles This should only be used for quick tight turns in loose soil conditi
53. eeded for all applications but it s available if you feel you ll need it 32 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop Atlas 2 Heavy Duty Stickout length is the length that the Left amp Right Drop shaft protrudes from the rear of the transmision with the adapter installed The measurementis the length that Atlas 4 Left Drop i the Atlas will accept Atlas 4 Right Drop FRONT INPUT SHAFTS 9 20 GM 39 SPLINE The 35 spline Atlas was designed to fit only the 2WD SM465 transmission This output shaft must be shortened to a length of 3 5 from the rear of the transmission This shaft must also be locked into position with a set collar The SM465 is 12 long and offers a 6 58 1 1st gear ratio The Atlas 2 speed is the only unit available for this transmission Due to the adapter length and the transmission size the cable shifters are not recommended for this transmission transfer case combination CLAMP COLLAR AA P N 716457 ADAPTER O A L 3 50 l 0 035 THRUST WASHER yy GM SM465 2WD TRANS OUTPUT SHAFT 35 SPLINES ORIGINAL 4 SPD OUTPUT BEARING Atlas 2 Speed P N A35 DIVORCED ATLAS The Divorce Mounted Atlas Transfer Case has been created to give you all of the great gearing options parts availability and SM465 SHAFT SPEC 1 I 1 4 STICK OUT MAX 35 5 MW GM mmm shi IE
54. eline modifications are required The installation does require the removal of the transfer case and disassembly of the console We also manufacture a drivetrain support tool that is a great accessory in aiding with the installation process of the RubiCrawler as well as any other drivetrain work Check out the Uni Raise at www advanceadapters com An unpacked TJ RubiCrawler kit Also hown with The 42RLE transmision rear housing after the stock ATF 4 fluid amp filter optional purchase items transfer case has been removed These photos show the rear housing of the 42RLE transmission and the removal of the stock spud shaft A slid hammer works the best however you could also pry the shaft out or make your own pulling tool shown far left Once the spud shaft is removed the stock tailhousing can also be removed Photos above show the rear housing of the 42RLE transmission with the stock tailhousing removed Note Removing the tailhousing will cause the lose of some transmission fluid The rear of the transmission needs to be cleaned and the mating surface of the RubiCrawler needs to have the Chrysler silicone included with RubiCrawler applied to the housing and then installed to the transmission The oil supply for the RubiCrawler comes from a high pressure source in the transmission and the o ring must also be installed to insure proper lubrication On average 4 quarts of ATF are required when installing a RubiCrawle
55. en the Atlas is overfilled with more than the recommended levels it will cause the unit to vent the extra oil out the breather Atlas oil levels should be monitored frequently The oil site tube should be marked to indicate proper oil level for the Atlas at the rotation installed in your vehicle The oil should be drained and replaced after the first 500 miles and then at intervals of 10 000 to 15 000 miles thereafter Atlas 2 and 4 speed Replacement Site Tubes We carry replacement parts for the Atlas site tube The site tubes are offered with two thread sizes to fit to the Atlas case Early cases were drilled and tapped for the 1 2 pipe fittings and the later cases for 1 4 pipe fittings The complete kit with the 1 2 pipe fittings is P N 301601 and the kit for the 1 4 pipe fittings is P N 301600 We also offer the individual fittings if a complete kit is not needed Breather Hose amp U Bolts Normally a new breather and breather hose is required to properly vent an Atlas 2 or 4 speed transfer case We can now supply you these items along with additional Atlas oil for the first oil change U bolt kits for the standard yokes are also listed below Breather amp Breather hose U Bolt kits includes two u bolts P N X11320 2SP Atlas kit P N X11340 1310 amp 1330 U Bolt kit P N X11324 48 Atlas kit P N X11341 1350 amp 1410 U Bolt kit P N X11342 1410 Strap kit Atlas Aluminum Knobs Atlas Black Anodized Knobs P N 303150 2 75 L
56. enorit Needle amp Taper Rollers Available Input Shaft Splines 10 21 23 25 27 28 Synchronizers Borg Warner 29 31 32 34 5 Available Input Shaft Splines 21 23 27 29 31 32 34 Rear Shaft H D or 32 Spline Tall Shaft iecore H D or 32 Spline Front Output 26 Spline or 32 Spline Front Output 22er 32 Spline RATIOS RATIOS Low Range ose at 2 0 1 or 3 0 1 or 3 8 1 or LOW RAN SC cooks Z0 227 221 Be SAP 4 3 1 or 5 0 1 neces 2 72 1 3 0 1 amp 8 16 1 aes 1 1 Ol ean bed du 2 72 1 3 8 1 amp 10 34 1 Dl duusese d 2 72 1 4 3 1 amp I1 70 1 LUBRICATION High Range 1 1 QUAINS Sois Liters 20 1 89 LUBRICATION CQUAIS wis Liters LENGTH COMPARISON 236 NP231 20 5 24 Rock Trac T C 15 1 4 LENGTH COMPARISON Dana 300 12 NP231 20 5 NP241 Rock Trac T C 15 1 4 Dana 300 12 ATLAS Atlas 2 speed Atlas 4 speed O A L with Short Short the Yoke list tailhousing tailhousing 1310 NON CV 11 380 16 356 1310 CV 11 8177 16 793 FLANGE 1300 10 199 15 175 1350 NON CV 11 442 16 418 1410 NON CV 11 630 16 606 1350 CV 11 815 16 791 FLANGE 1410 10 067 15 043 Atlas case Operating Temperature The case temperature will vary with the type of driving you are doing with the vehicle as well as outside air temperature and air flow around the drivetrain The numbers listed below are what we feel are the normal operatio
57. er the length of the output shaft or the length of the stock adapter being too long for your application The following pages list the different available input splines for the Atlas You must make sure that your transmis sion has the proper bolt pattern and proper output shaft stickout length Incorrect output shaft lengths or improper indexing adapters can cause internal damage to the unit voiding the warranty Please read the following information to verify the correct application The Atlas 2 speed diagram left has a highlighted section in red This highlighted portion of the Atlas 2 speed is similar to what is EE B2 a zzz Shown under each input spline option on the follow ing pages These inputs show the recommended mating spline length requirements The Atlas 4 speed has a similar type of input to mate to the transmission We have listed the shaft length allowed past the adapter housing that the 4 speed will ac cept also call stickout length b A Please confirm your spline engagement to avoid any problems Input shaft changes Each Atlas is custom built to fit your vehicle speci fications Many times we find that customers end up changing drivetrain components which then also requires changes to the Atlas The most common change is the input shaft spline to match a new transmission The Atlas input can be changed without to much difficulties We offer instructions that can be sent to you or you can view the procedure
58. ese shifters have been designed mainly around stock vehicles Vehicles with body lifts greater than 1 may require more than the usual modifications for proper fit of the shift handles All twin stick shifters with the exception of the cable shifter are included at no additional cost when an Atlas is purchased The 4 speed shifters are basically the same as the standard Atlas shifters except for the extension tube and shift rail connecting links which are longer to compensate for the added length of the transfer case SHIFTER SOLD WITH AN ATLAS 4 SPEED P N 344000 Universal Atlas 4 speed Right or Left shifter P N 344002 TJ Automatic Atlas 4 speed shifter P N 344003 TJ Manual Atlas 4 speed shifter P N 344004 Bronco Atlas 4 speed shifter P N 344005 ZJ Atlas 4 speed shifter P N 344006 Explorer and Bronco II Atlas 4 speed shifter P N 344007 XJ Atlas 4 speed shifter P N 344008 JK Atlas 4 speed shifter additional cost P N 303009 4 Cable Shifter additional cost P N 303020 4 TJ Cable Shifter additional cost 4 SPEED SHIFTER OPTIONS 4 SPEED REDUCTION HOUSING SHIFTER The planetary reduction portion of this box is a non synchronized unit YOU MUST COME TO A COMPLETE STOP BEFORE SHIFTING THE PLANETARY For the manual transmission the shifting procedure should be to stop the vehicle then shift the planetary If the shift is unsuccessful then feather the clutch as you pull on the shift lever The unit should slide easily into gear For an automa
59. exed into the tailhousing When installing the speedometer housing lube the o ring that contacts the Atlas tailhousing with a 38 bit of oil This will prevent the o ring from being nicked upon installation or rotation causing this housing to leak FINAL INSTALLATION SHIFTER ASSEMBLY Speedometer Problems No matter what speedometer gear you use you must make sure that the teeth of the speedometer gear have proper contact with the Atlas output shaft The speedometer housing can be rotated to achieve proper contact Note There are three rotation possibilities Many of the Jeep speedometer housings offer index numbers that reference to the gear tooth count By lining up the retainer clip with the proper index number the speedometer gear will work properly If your housing does not have these index numbers proper engagement can be obtained by rotating the speedometer housing until the speedometer gear meshes with the output shaft The slots on the housing will then line up with the retainer clip If this is not done the speedometer will not engage properly T Speedometer Installation The Jeep TJ speedometer is a tight clearance fit to the Atlas shift control One option for clearance is to plug in the connector while the speedometer is rotated away from the shift control and then rotate the assembly back into position for the speedometer gear engagement The other option is to keep the white portion of the speedometer rotated 180 degrees from wher
60. f our castings equipped with the dual bolt pat tern you will have the following rotation options Atlas 2sp Left Drop STD or Flat Case Rotation Atlas 2sp Right Drop STD or Flat Case Rotation degrees mL E degrees Atlas 4sp Left Drop Atlas 4sp Right Drop Possible Rotations Possible Rotations degrees 5 degrees degrees 12 degrees CENTERLINE OF HOUSING degrees degrees degrees degrees degrees degrees degrees Special Adapter Rotations Shorty 4L60E Adapter Atlas 2 speeds Left STD Case 10 20 amp 30 degrees Left Flat Case 2 amp 12 degrees Right STD Case 12 degrees Right Flat Case 4 degrees degrees degrees degrees degrees degrees degrees FOOT OF CASTING OR TRANSMISSION VIEW FROM REAR OF CASTING OR TRANSMISSION ROTATION OPTIONS 24 TAILHOUSING OPTIONS REAR TAILHOUSING OPTION Standard Atlas Tailhousing The standard Atlas transfer case comes with a rear tailhousing that accepts a stock Jeep speedometer from Jeep vehicles 1982 amp newer Atlas units ordered for earlier Jeeps or other vehicles can order a mechanical drive speedometer housing This housing is the same as an early style Jeep To connect to this housing a special cable fitting may be necessary The speedometer provision on the Atlas also allows you to calibrate your speedometer for tire and gearing changes The chart on Page 28 lists these options The Atlas 2 speed tailhousing is P N ALT32 Ifa speedometer is not
61. fference of 3 0 Since the Atlas is 3 0 shorter than your stock transfer case your rear driveshaft would then need to be lengthened 3 0 This difference is now added to the measurement taken from your stock driveline as recommended in the Preparation section You would now have your new rear driveshaft length FRONT du LE Measure the stock transfer case from the front yoke face to the surface of where the transfer case bolts to the adapter housing Fig D Write that measurement down The front yoke on the various stock transfer cases can either be a positive measurement protrudes out from the adapter input face or a negative measure ment recessed inward from the adapter input face Most gear driven transfer cases will have a positive yoke measurement and most chain driven transfer cases will have a negative yoke measurement The Atlas measures approximately 2 positive offset from the face of the front yoke to the transmission adapter input Fig D Front Measurement Example Fig D This stock transfer case our example measured a negative 1 1 4 Adding that to the Atlas measurement of positive 2 the difference is 3 1 4 Since the Atlas front yoke on this application is 3 1 4 closer to your front axle you would then need to shorten your front driveshaft i TOP this distance This difference can now be subtracted from the stock driveshaft ip bvs new meg yoke div spats measurement taken from your stock dri
62. g low range without the Low Range switch hooked up P N 300378X Low range pigtail for Jeep 300377 will not light up 4WD indicator in high range Note This is a connector kit which requires you to solder and assemble the pigtail P N 300377 Control module for Jeep JKs Ww g retains all stock features when an Atlas is installed 2012 and Up Jeep JK Autos JK 2012 and newer Jeeps equipped with an automatic transmission will also require a Body Control Module flash to operate correctly with the new Atlas transfer case Jeep coded the stock transfer case ratio of either the 2 72 1 or the 4 0 1 into this module and any different ratio in the transfer case will put the vehicle into a limp mode The Body Control Module is located under the steering column access panel The Module can be removed and shipped to Burnsville Offroad 3513 Highway 13 W Burnsville MN 55337 952 890 3990 The program flash is approximately 100 00 and you will need to know the ratio you want to use on the Atlas Unfortunately the Atlas 4 speed is not an option in these newer JKs with the automatic The exact ratios for the Atlas are required for reprogramming the module We round up or down to the decimal on our ratios however the Jeep computer module will accept the three places right of the decimal The ratios are as follows 2 0 1 is exactly 30 2 087 1 3 0 1 is 3 030 1 3 8 1 is 3 824 1 4 3 1 is 4 286 1 and 5 0 1 is 5 048 1 SPEED SENSOR AND LOW RANG
63. hift fork replacement We have used several different designs on the Atlas shift forks over the years Units produced in the early years had a gusseted steel shift fork and under hard use these could be bent and then could cause the Atlas to pop out of gear in certain circumstances Today we use a gusseted cast fork that is able to withstand the wear and tear of the various shifting woes To upgrade to the new cast forks order P N 301550 T Site tube replacements The site tube was a feature added to the Atlas early on to provide 7 a quick glance at the oil level The level was always an issue due to the various rotation options of the Atlas The site tube has only had one change on the Atlas which is the fitting size on the case We have changed the fitting material and the tubing material several times which does not effect anything on the case P N 301600 1 4 fittings AC ers P N 301601 1 2 fittings dell Atlas oil Amsoil MTF 75 90 GL4 P N 303200 a Tar Lube Torque MTF is also a oil that we have used in the past but no longer stock APPAREL We are constantly updating and adding new apparel Most items have an Advance Adapters logo or Atlas transfer case logo We buy quality apparel products since they represent our name Check out our new apparel online at www advanceadapters com under the Apparel Category Most apparel is stocked in sizes ranging from Medium to XXXL The apparel size is included in the p
64. high position and the Front knob should be in the neutral position After a few miles in 2WD High we recommend that you shift the Front shifter knob into High putting you in 4WD High On manual locking hubs to achieve any type of 4WD your hubs must be locked The Front shifter handle should shift smoothly in and out of neutral and High IF THE SHIFTER DOES NOT ENGAGE EASILY DO NOT FORCE IT Your linkage my need to be adjusted When you are shifting out of 4WD high the Front knob must always be disengaged first If the shifter feels tight or sticky press in the clutch or shift to neutral automatic transmission or simply straighten the front wheels The vehicle should be moving forward when shifting the Atlas When shifting into Low range REMEMBER the following The vehicle should be at a slow roll forward no faster than 5 miles an hour Speeds faster than recommended could cause personal injury like unloading the rear payload into the front seats or damage to the drivetrain which is not only embarrassing but expensive The Atlas has the unique feature of 2WD low with the rear axle or the front axle At any time while driving in low ratio you can disengage either the front or rear by shifting the respective handle into neutral Shifting an Atlas with an Automatic transmission While the vehicle is slowly moving forward place the transmission into neutral and engage the front or rear control into Low The Atlas is a synchroniz
65. his manual has been put together with the best possible information available to us Advance Adapters cannot accept the responsibility for vehicles and applications that are not standard The contents of this brochure have been proofread before printing to minimize errors We cannot be held responsible for errors overlooked Please feel free to contact us with any suggestions or comments you may have regarding any portion of this manual The information that you provide us could be useful in assisting other customers The word Jeep amp Jeep Grille as used in the contents of this manual have been recognized as a registered trade mark of Chrysler Corp The artwork and copy contained in this manual is the property of Advance Adapters Inc and any use in part or in whole must obtain written permission from Advance 2 Adapters All contents of this catalog have a copyright and are reserved for Advance Adapters Inc only TABLE OF CONTENTS b et s ATLAS SPECIFICATIONS ATLAS 2 SPEED ATLAS 4 SPEED CASE CASE Male Es 356 16 Heat Treated Aluminum Material 356 T6 Heat Treated Aluminum re 1 10 Ibs dry VVOISDE 135 Ibs dry INTERNAL COMPONENTS INTERNAL COMPONENTS GEAFS cs Helical Cut e ner amen Helical Cut PENES se Needle amp Taper Rollers Planetary Assy 6 Pinion Helical design Synchronizers Borg Warner serrer t
66. ications we ve listed a couple of options when coupling the transmission to the transfer case The different options usually come about from different adapter lengths giving you the choice for a longer or shorter drivetrain With the diversity of adapters we offer we could actually offer up to 5 or 6 ways to couple some of the different transmissions to the 11 different Atlas input shafts however we are trying to simplify the choices and applications This chart along with the Atlas input spline information listed on the proceeding pages should help with your Atlas transfer case selection ATLAS TRANSFER CASE ADAPTER SELECTION CHART FOR GM FORD JEEP amp DODGE MANUAL amp AUTO TRANSMISSIONS ADAPTER KIT ADAPTER HOUSING OR STOCK HOUSING ATLAS INPUT SPLINE ATLAS TRANSFER CASE ADAPTER SELECTION CHART FOR GM FORD JEEP at DODGE AUTOMATIC TRANSMISSIONS ADAPTER KIT ADAPTER HOUSING OR STOCK HOUSING ATLAS INPUT SPLINE GM SM420 4 SPEED 50 9702 2 23 GM TH350 2WD TRANS 50 6300 2 3 23 10 5 CASE LENGTH 5 25 ADAP 21 5 CASE LENGTH 50 6802 3 23 GM SM465 4W D 10 SPL 51 9807 7 10 GM TH350 4W D TRANS 50 6304 2 23 12 CASE LENGTH 3 5 ADAPTER 21 5 CASE LENGTH AS 6800 5 27 GM SM465 2W D 35 SPL 51 9807 47 35 GM TH400 2W D TRANS 51 6400 4 32 12 CASE LENGTH NOTE 9 3 5 ADAPTER SHAFT STICKOUT OF 5 NOTE 9 FORD T amp C
67. interfere with the Atlas input GM Transmissions GM switched the spline count on some of their transmissions to the 29 spline output The splines on these transmissions were the same as what Dodge had used on the NV4500 transmission So the 29 spline input for the Atlas will work with all of these GM and Dodge transmission equipped with a 29 spline output shaft ZF S6 650 The ZF manual 6 speed is a 29 spline transmission when coupled to the Duramax and the 8 1L This transmission can be directly mounted to the Atlas transfer case The Atlas must be equipped with a Chevy case configu ration and will bolt directly to the stock transmission 4WD adapter The VSS tailhousing option would provide the GM computer the speedometer signal for this application Allison 4WD These 5 and 6 speed automatics are also a 29 spline transmission when coupled to the same Duramax and the 8 1L The Atlas must be equipped with a Chevy case configuration We offer two modified stock adapters for the Allison transmission These adapters provide a rear speed sensor in the adapter that always sends the output shaft speed signal to the computer We have found that putting the sensor in the tailhousing on these transmissions with the various low ratios will cause the computer to read it as transmission slippage and throw trouble codes The adapters we offer are reworked OEM components and we require your stock tailhousing as a core Part numbers for these adapters are 50 9420
68. las will accept FLUSH STICK OUT MAX GM 10 SPLINE The 10 spline Atlas input was designed to fit only the 4WD version of the SM465 transmission This output shaft protrudes approximately 2 1 2 from the rear of the transmission When coupling an Atlas to this transmission you will need one of our adapter housings the SM465 gasket and fasteners to 7 ET bolt the casting to the transmission P N 51 9807 This adapter hn housing measures 3 1 2 long and is the shortest adapter that we offer 77 B for the SM465 The Atlas 2 speed is the only unit available for this trans mission Due to the adapter length and the transmission size the cable shifters are not recommended for this transmission transfer case com bination Atlas 2 Speed P N A10 FRONT INPUT SHAFTS GM 27 SPLINE The 27 spline Atlas was designed for transmissions with a 27 spline output The TH350 Powerglide 700R and 4L60E transmissions are the most common GM transmissions equipped with this 27 spline output These transmissions have various Output shaft stickout lengths depending on the vehicle that the transmission was originally removed from 27 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop A27 Stickout length is the length that the shaft protrudes from the rear of the transmision Atlas 4 Left Drop A427L with the adapter installed
69. mber Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop A21 Stickout length is the length that the shaft protrudes from the rear of the Atlas 4 Left Drop A421L transmision with the adapter installed The measurement is the length that the Atlas 4 Right Drop A421R Atlas will accept 1 2 Spacer Adapter P N AS 8610 not need on Atlas 4 speeds JEEP amp DODGE 23 SPLINE amp 2012 JEEP 26 SPLINE STOCK JEEP TRANSMISSIONS Stock Jeep transmissions 1980 amp up with a 6 cylinder or larger engine were normally equipped with a 23 spline output shaft except Peugeot Since the Atlas was designed as a Jeep heavy duty low geared transfer case replacement it will bolt up directly to the stock Jeep transmission tailhousing that is equipped with the 23 spline output shaft In these year Jeeps the stock transfer cases used were both a driver s side left hand drop and passenger side right hand drop front driveshaft The units listed accommodate both stock transfer case configurations Some of the later model Grand Cherokees with the A518 A500 amp AW4 transmission will have some spline depth interfer ence On these applications you may be required to use our spacer adapter P N AS 0404 Failure to use this plate when necessary will cause damage to the Atlas The Atlas 23 spline transfer cases can be ordered in any low gear ratio offered for a 2 speed Atlas The 4 speed Atlas is also an option for this spline co
70. mixed with gears that were not full fillet This design adds up to a 20 strength upgrade Atlas 3 8 Gears are now all full fillet design These gears should not be mixed with gears that were not full fillet This design adds up to a 2096 strength upgrade ATLAS UPDATES 43 ADVANCE ADAPTERS INC RUBI This unit fits Jeeps 2003 to 2011 with the 42RLE automatic overdrive transmission This new reduction unit replaces the stock 42RLE tailhousing with a 6 gear planetary reduction box featuring a 2 72 low range This is a true bolt in doubler that couples to the stock Jeep transfer case or an existing Atlas transfer case Features The RubiCrawler increases your available gear ratios allowing you to gear your Jeep to the terrain in which you re wheeling on The various ratios will allow you more control of the vehicle which results in extreme off road performance while maintaining a fun and safe offroading experience Ratios with a Stock New Process 231 241 are a 2 72 1 and a 7 40 1 Ratios with a Stock NP Rocktrac are a 2 72 1 4 0 1 and a 10 88 1 Shifting the RubiCrawler The RubiCrawler shifting mechanism utilizes push pull cable technology for a smooth and easy shift The universal cable shifter is included with the purchase of your RubiCrawler The universal shifter should be used if your vehicle is equipped with an Atlas transfer case We also offer a twin stick cable shifter These kits are designed to fit the stock Jeep TJ and JK c
71. n new installations having less than 10 to 20 miles on the unit and in a vehicle that was flat towed We now recommend that a new unit must have the break in fluid replaced which is after the first 500 driving miles This allows the bearing to seat properly to the bearing race It also allows the oil to circulate through the unit to lubricate areas that were assembled with assembly lube If you plan on flat towing we actually prefer that you remove the driveshafts from the vehicle This eliminates any possible chance of bearing failure on your Atlas 2 speed due to lack of oil circulation PLEASE NOTE that under absolutely no circumstance should an Atlas 4 speed be flat towed without removing the driveshafts Damage to the planetary assem bly and the additional needle bearings will occur COMMON INSTALLATION MISTAKES INSTALLATION PROCEDURES FOR ALL VEHICLES Before the actual installation begins you should read the installation and operating procedures of your new transfer case Please verify that ALL features such as input spline and case configuration left or right hand drop are correct Also inspect the unit for any damage that may have occurred during shipping This section of the manual deals with the general installation procedures of the Atlas Specific installation instructions for many vehicles are also on our website at www Advanceadapters com or provided for you with your unit Please read all instructions before installing LUBRICATI
72. n obtaining the right speedometer drive gear As you can see their are two types of speedometer gears both long and short We measured them by the overall length of the speedometer gear Long being 4 3 and short being 2 2 The speedometer housings that accept these gears are not interchangeable For example If your stock vehicle had a 2 2 gear you cannot put a 4 3 gear onto that speed o drive housing IlIlust A Short Electronic type If you are installing an Atlas in a 1987 or newer Jeep and have not changed your tire size or your axles your stock speedometer drive gear would remain the same However if a new axle ratio and or tire size is considered see Fig E on Page 28 We offer many stock gear options for your speedometer housing some being in limited supply Listed on the bottom of Page 29 are the gears we offer If your axle ratio and tire size requires a different combination see Fig E amp Fig F Please contact your local Jeep dealership or refer to the gears that we offer Long Cable type When installing a speedometer gear with either 39 40 41 or 42 teeth the gear and the housing must be installed separately These are all large diameter speedometer gears By first installing the gear into the tailhousing you will be able to tilt the gear shaft up allowing you to position the gear past the Atlas output shaft Once this gear is in place the speedometer housing must be aligned with the speedometer gear shaft and ind
73. n of the over all length and the linear distance of the front yoke to the transfer case input face 42 ATLAS 4 SPEED 18 8 OAL ATLAS 2 AND 4 SPEED DIMENSIONS ATLAS UPDATES The Atlas was first released in 1995 Over the years we have made improvements design changes and expanded the vehicle applications The Atlas holds a strong reputation as the ultimate upgrade for an offroad vehicle We have continually strived to improve on the Atlas where we perceived any short coming or potential weaknesses and have always tried to evolve on the overall performance the case provides the end user The dates or serial numbers listed below are significant changes in the Atlas and could effect the replacement parts needed if you are rebuilding or ordering parts for an Atlas transfer case 1 1 2006 5 4 2006 11 30 2007 9 3 2009 1 1 2010 9 27 2010 7 22 2010 8 19 2010 9 10 2010 11 23 2010 2 2011 3 2011 12 16 2011 2 25 2011 3 15 2011 1 24 2012 3 9 2012 3 2012 4 2012 4 24 2012 5 10 2012 10 2 2012 10 18 12 1 1 2013 Cast iron forks Site tube change was 72 6 fitting and is now a Change over to 32 spline input gear on all ratios All number from here on started with a G The Atlas 6 0 gear set was also discontinued at this time Heavy duty 32 amp 29 input shafts introduced 300M material Serialization of cases on the mill 6 digit serial numbers 9
74. n of the transmission output shaft must be removed The Atlas 2 speed is the only unit available for these transmissions A body lift is recommended SHAFT RECESS Left Side Front Driveshaft Atlas 2 Speed P N A28 1 5 8 MIN T 15 7 2 the C4 transmission 28 5PLINE FORD BRONCO S N RK V8 n ci REMOVE 0 375 FOR C4 AUTOMATIC APPLICATIONS C4 AUTO 3 660 MANUAL TRANS 4 035 Left Side Front Driveshaft Atlas 2 Speed for P N A28C4 FRONT INPUT SHAFTS l6 FORD 31 SPLINE SHOULD BE FLUSH AT THE TAIL HOUSING MATING SURFACE The 31 spline Atlas was designed to fit the 4WD Full Size a Ford transmissions The stock transmissions used in these vehicles were normally coupled to either a NP205 NP208 or Borg Warner 1356 The bolt pattern on these transmission tailhousing adapters is identical to a stock Jeep Ford used various output shaft stickout lengths Caution should be used in order to avoid the spline portion of the shaft from bottoming out in the Atlas input shaft Some applications that have an output shaft stickout past the 3 5 tailhousing will require a 1 spacer adapter P N AS 0404 Late FE model full size Fords with the Borg Warner 4406 transfer case and the vacuum activated electric lock front axle will require a low ae range switch on the Atlas shift housing and some electrical work for the front axle
75. nal temperatures temperature gauge to your Atlas and are getting temperature variances from what we have listed you should first make sure your If the gauge is reading correctly and your case temperature is greater than 15 than what we have gauge is accurately calibrated listed please call one of our technicians Normal Operating Temperature 160 175F Vehicle using high horsepower or pulling a heavy load 190 220F Maximum recommended case operational temperature 230 240F If you do connect a 3 ATLAS SPECIFICATIONS d ATLAS INFORMATION AND ACCESSORIES Oil Specification The Atlas is shipped DRY Before operating your Atlas please fill with the recommended gear lubricant Amsoil MTG GL 4 Torco MTF GL 4 or any other GL 4 rated synthetic gear oil If you are unable to find these lubricants one of the following synthetic oils can be substituted as a temporary fix until the proper fluid can be obtained Castrol Syntec 5w 50 or Mobil 1 Synthetic 15w 50 The recommended oil capacity for the Atlas 2 speed is 2 quarts and the Atlas 4 speed is 2 1 2 quarts The Atlas does not offer any type of weep hole to verify the oil level Therefore we have supplied your unit with a site tube to aid in determining the correct fluid level Once the required quarts are put into the Atlas we recommend marking the oil level on the site tube We like to use a small zip tie as a oil level marking device Note Wh
76. ons The only shift position that is not available is Front 2WD high 4 Speed Atlas Reduction Housing This is a non synchronized shifted unit To shiftthe reduction housing portion of the Atlas the vehicle should come to a complete stop and the transmission must be in a neutral position Once the vehicle is stopped you can then engage or disengage the planetary gearing The shifting of this unit is designed for a cable shifter OPERATING AND SHIFTING OPERATING CONSIDERATIONS The low gear reduction of the transfer case will help to ease you through the toughest terrain you can find The essentials of good 4 wheeling is the sheer ability to maneuver at a safe speed while retaining your line of attack on the course in front of you The slower rate of approach will not only keep you in the seat but also keep the tires on the ground for the best possible performance If you are considering the Atlas or have purchased one already it is sure to change the way you 4 wheel KNOW YOUR LIMITS Please begin with mild terrain and experiment safely to your new level of potential The low reduction will not only slow you to a tactical approach but will also increase the expected output of your current equipment Your response from the accelerator may surprise you The crawl ratio is a torque multiplication In some transfer case replacements it can be an increase of more than twice that of the original potential KEY CONSIDERATIONS Brakes On flat
77. onsoles These shifters are an additional charge but are best suited for most installations The Jeep TJ twin stick shifter replaces the standard mechanical linkage We have designed a twin stick shifter that comes through the stock console for a clean installation that operates both the RubiCrawler and the stock NP231 or NP241 transfer case The twin stick JK shifter also provides a twin stick shifter through the stock console This kit retains the stock transfer case cable with the addition of the new RubiCrawler cable The RubiCrawler and shifter kits are ordered as a combination The kit numbers below include the RubiCrawler unit as well as the shifter kit P N RUBI KA JEEP JK STOCK TRANSFER CASE Twin Stick Shifter P N RUBI JK UNIV JEEP JK ATLAS TRANSFER CASE Universal Shifter RubiCrawler P N RUBI TJ231A JEEP TJ STOCK 231 TRANSFER CASE Twin Stick Shifter P N RUBI TJ241A JEEP TJ STOCK 241 TRANSFER CASE Twin Stick Shifter P N RUBI TJ UNIV JEEP TJ ATLAS TRANSFER CASE Universal Shifter RubiCrawler Additional Accessories P N 42R360 1quartA T F 4 quarts recommended P N 42R370 Newtransmission filter P N 42R650 JK Black anodized aluminum knobs twin stick shifter kit We have also designed an electronic interface assembly that integrates the RubiCrawler into the Jeep Wranglers electronics The primary function of the RubiCrawler Control Module is to allow the Rubicon locking differentials and disconnecting sway bar JK only to operat
78. panion flange bolts to be installed through the yoke before the yoke is installed onto the transfer case This depends on the series of companion yokes used If the flange yoke is currently installed on your transfer case you may be required to first loosen the yoke retaining nut pull the yoke away from the transfer case enough to install the companion flange bolts Once the bolts are in place a new lock nut should always be installed and torqued to 150 ft Ibs to secure the yoke to the transfer case If any yoke nut is ever removed from the shaft for any reason it should always be replaced with a new one When installing a new yoke the rubber seal washer should be used along with a small amount of silicon 0 oil leakage down the shaft splines YOKE OPTIONS 2 000 Yoke Modifications Changing the style of yokes on the Atlas HOLE transfer case may require your new yoke to be modified When installed on an Atlas the yoke will load up against a tapered roller bearing Some yokes require a chamfer to be machined to clearance the cage of this bearing The yoke drawing shows the required machining on these yokes 1 6 5 2 128 0 262 2 NON CV 1350 amp 1410 1310 OPTIONAL YOKES THAT WE DO NOT STOCK Front Yokes for 26 Spline shaft 1330 series non C V Spicer P N 2 4 3571 amp C R 15635 1350 series non C V Spicer P N 3 4 5751 amp C R 15635 There are no C V yokes availabl
79. r Note FJ Cruisers with an auto trans will require a VSS speedometer connection Manual transmissions applications will need speedometer verification requirements 23 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 Left amp Right Drop A23 375 Stickout length is the length that the shaft protrudes from the rear ofthe transmision with the Atlas 4 Left Drop A423L 500 adapter installed The Atlas 4 Ri ght Drop A423R 500 measurementis the length that the Atlas will accept OE Military amp Special Applications We are committed to offer the you the best transfer case available It is for this reason that the Atlas is the transfer case used in a production built vehicle for the off road enthusiast This manufacturer uses the Atlas because of its reputation and years of reliability The Atlas has also been used in several military prototype vehicles and is currently in use in overseas production vehicles This military application is why we now offer the Atlas with a 300M output upgrade The vehicle is approximately 12 500 Ibs requiring the added strength to the output shaft The Atlas has been proven flawless in these applications As you can see we are very receptive to new applications for the Atlas and we are always willing to make changes if needed to fit new applications If you do not see an Atlas exactly to fit your needs please contact us directly FRONT INPUT SHAFTS 2l 22 ATLAS RO
80. r T 5 RUBICRAWLER INFORMATION Photos above show the RubiCrawler bolted in place The unit is the exact same length as the stock tailhousing and has the same crossmember mounting location This allows the stock transfer case to be reinstalled into its original location without any driveshaft or crossmember modifications The RubiCrawler offers two bolt pattern rotation options both were used in the Jeep vehicles We recommend that the stock rotation be retained Clocking the transfer case changes the driveline angles and we have found on some new installations that if the transfer case is re clocked up closer to the floor board vibrations in the drivetrain can appear Logically most conclude it is because of the new RubiCrawler however the transfer case rotated different from stock will cause drivetrain vibrations and require axle pinion angle adjustments i l This section of 4 photos show some of the shifter brackets and cables connected to the RubiCrawler and the transfer case The cables come with heat shields to protect them from the drivetrain 46 RUBICRAWLER INFORMATION Before and after look at the stock Jeep TJ amp JK consoles The photos below them are the new shifter kits installed Shifter handles fit cleanly through the stock console for an OEM look One handle controls the factory transfer case and the second is for the RubiCrawler TE X Jeep TJ Jeep JK with billet aluminum knobs P N 42R650 Tran
81. r from the 23 spline data 2004 ZJ 4 7L 5 45RFE NV247 stock transfer case approx 1 recessed output shaft Requires Long Atlas 23 input 2004 Ram 5 7L 5 45RFE NV244 stock transfer case approx 1 4 output shaft stickout with 1 55 spline 03 10 5 45RFE Requires Short Atlas 23 input 2001 Ram 45RFE NV231 stock transfer case approx 1 2 output shaft stickout with 2 0 spline Requires STD Atlas 23 input amp AS 8603 2004 Durango 5 45RFE 3 8 output shaft stickout Requires Short Atlas 23 input 2005 amp UP Manual Jeep 6 speed NSG 370 23 spline Wrangler 4 cyl amp 6 cyl transmission gear ratios of 4 459 2 614 1 723 1 2 1 0 838 amp R4 06 output shaft approx 210 positive stickout Honsel is cast into passenger side Requires STD Atlas 23 input 23 Spline Input For Part Number Transmission Shaft Stickout Length Atlas 2 STD Left amp Right Drop A23 Atlas 2 LONG Left amp Right Drop A23LONG Atlas 2 SHORT Left amp Right Drop 2 Stickout length is the length that the shaft protrudes from the rear of the transmision with the adapter installed Atlas 4 STD Left Drop A423L The measurementis the length that Atlas 4 STD Right Drop A423R heAlas wil accept Atlas 4 LONG Left Drop A423L LONG Atlas 4 SHORT Left Drop A423L SHORT 1 Spacer P N AS 0404 3 4 Spacer P N AS 8603 1 2 Spacer P N A 8610 i 3 8 STICK OUT MAX STOCK DODGE TRANSMISSIONS
82. red roller bearings The Atlas also features a unique twin stick design to deliver crisp quiet operation The Atlas transfer case offers you the ability to customize the transfer case to your vehicle We offer several upgrades options and different configura tions for this transfer case Listed on the following pages is all the informa tion to make your custom made to order Atlas the ultimate gear driven transfer case ATLAS 4 SPEED DESCRIPTION The 4SP has essentially two parts The first is the reduction housing This housing holds a planetary assembly that has a gear ratio of 2 72 1 when in low range and a 1 1 in high range It has one shifter coming out of the top to select the desired range The planetary is not a synchronized shift on the fly design and must be oper ated when the vehicle is stopped The main case still retains the shift on the fly capability just like the standard Atlas The reduction housing shifter is designed for a cable shifter The second part of the 4SP may look the same as the standard Atlas but it does have some differences The main case of the 4SP is the same raw casting but has some machining variations to make it into a 4SP The main case functions independently from the front reduction housing and retains all of the normal Atlas features front and rear outputs controlled independently and the front only option All of the gears are the same as the Atlas 2 speed The strength of this unit
83. rience regarding the transmission towing position are as follows please also verify in your owners manual what the vehicle manufacturer recommends Automatic transmissions should be left in park Manual transmissions should be left in any gear If you plan on flat towing an Atlas 2 speed equipped vehicle and do not wish to stop to circulate the oil we actually prefer that you remove the driveshafts from the vehicle This will prevent any damage that may occur to the internal components due to lack of normal oil circulation The ATLAS 4 speed should never be flat towed without removing the driveshafts The planetary unit and additional bearings do not receive the normal oil flow as they would under normal driving conditions and therefore damage will occur MAINTENANCE Atlas oil levels should be monitored frequently The oil site tube should be marked with a zip tie to indicate proper oil level for the Atlas at the rotation installed in your vehicle The oil should be drained and replaced after the first 500 miles and then at intervals of 10 000 to 15 000 miles Note If your primary use is extreme offroading you may consider intervals as frequent as every engine service 11 CONSIDERATIONS TOWING AND MAINTENANCE ATLAS 2 AND 4 SPEED DIMENSIONS 13 80 The Atlas measures approximately 14 from the center of the input to the outside edge of the main case The Atlas 4 speed has the same case dimensions as the 2 speed with the exceptio
84. rom us to use these transmissions with this stock 27 spline 4WD output shaft 7 H 1 4 STICK OUT MAX 2 Z 7OOR amp 4L60 2WD When obtaining a 700R out of a 2WD vehicle the stock output shaft will be too long These transmissions would be better suited to either switch to a 4WD 700R output shaft and use the adapter housing listed above or use Part No 50 6303 3 6 long or 50 9102 1 5 long Both of these kits require the installation of a new output shaft which switches the output spline to a 23 spline See the 23 Spline section 4L60E 4WD w non removable Bhsgs When obtaining a 4L60E u pe NEN out of a 4WD vehicle the output shaft stickout length should be vz 2 75 from the rear square flange of the transmission Adapter IIIE housing P N AS 9111 2 5 long can be purchased from us to use this D 177 transmission with this stock 27 spline 4WD output shaft Note On these transmissions you must use a reluctor kit Part No 716073 j Atlas 2 Speed Input shown i FRONT INPUT SHAFTS 1 967 17 lo 4L60E 2WD amp 4WD w non removable Bhsg When obtaining a 4L60E out a 2WD vehicle the stock output shaft will be too long or if you have a 4WD transmission and would like to use an adapter housing with the reluctor as part of the kit you can purchase P N 50 0404 4 6 long This kit requires the installation of a new output shaft which switches
85. s designed to fit Jeeps that were originally equipped with a 4 cylinder and some 6 cylinders Jeeps 1987 amp up with a 4 and some 6 cyl used 1 of 3 transmissions the AX5 the Peugeot or AW4 The output shaft on these transmissions are either flush or protrude approximately a 1 2 from the stock transmission adapter The AW4 transmis sion was most commonly found in the early Jeep Cherokees All 4 cylinders manual transmission and most 4 0L 6 cylinder non high output engines seem to be 21 spline transmissions however we recommend verifying the spline count on these transmission applications The Jeep high output 4 0L 6 cylinder with the AW4 should be a 23 spline output shaft NOTE The 21 splines on these transmissions are very small in diameter and thus we have seen the stock output shaft break on many engine converted vehicles When coupling an Atlas to these transmissions the factory adapter is used Due to the different output stickout lengths vehicles equipped with a Peugeot and AW4 will require a 1 2 spacer plate to obtain proper spline engagement In 1997 late model AX5 transmissions were changed to have an output shaft that protrudes a 1 2 from the stock tailhousing Although this transmission can bolt directly to the Atlas 2 speed transfer case we recommend using the 1 2 spacer plate for transfer case shifter clearance This spacer plate should only be used on an AX5 that has a 1 2 output shaft stickout 21 Spline Input For Part Nu
86. s include our seal number plus the Chicago Rawhide amp National seal numbers ATLAS YOKE OPTIONS Individual AA Seal O E Seal A New Atlas Yokes PIN s PIN s Front Yokes 26 Spline P N A1310 26 P N 300477 P N 300501 NAT 450185 32 Spline Yokes P N A1310CV P N 300475 P N 300502 CR 18817 or P N 1350 P N 300472 P N 300473 NAT 472015 P N A1350CV P N 300485 P N 300473 CR21164or 1410 series non C V Straps P N A1410 P N 300483 P N 300473 NAT 472015 1410 series non C V U bolt P N A1410U P N 300488 P N 300473 Flange Yokes 32 Spline 1310 1330 1350 series P N AF1300 P N 300470 P N 300473 CR 21164 or CV amp non C V 1410 series non C V P N AF1410 P N 300471 P N 300473 NAT 472015 1410 Flange yoke is drilled and tapped for 4 12mm x 1 25 bolts on a 3 75 diameter and has a 2 75 female index for the mating yoke The 1300 series flange yoke is shown on the next page Yokes with the asterisk are an additional cost on new Atlas orders Companion yokes for the flange yokes listed above 1310 1330 amp 1350 C V and non C V flange yoke Spicer companion yoke numbers are as follows 1310 C V P N 211229x 1310 non C V P N 2 2 939 1330 C V P IN211631x 1330 non C V P N 2 2 1369 1350 C V P N 212024x 1350 non C V P N 3 2 1579 1410 non C V flange yoke Spicer companion yoke number is 3 2 439 1410 non C V Flange yoke may require the com
87. sfer Case Shifting The transfer case can be shifted from 2 wheel drive to 4 wheel drive HIGH while the vehicle is moving To shift the transfer case into 4 wheel drive LOW you must shift the transmission to neutral and the vehicle speed must be below 2 mph The transfer case can be shifted at a complete stop but it is easier to shift the unit when at a very slow roll RubiCrawler Shifting The RubiCrawler must be shifted when the transmission is in neutral and the vehicle speed is less than 2 mph The RubiCrawler can be shifted at a complete stop but it is easier to shift the unit when at a very slow roll DO NOT try to FORCE the shift levers as serious damage to the shifters or unit can occur Maximum Speed The RubiCrawler should not be operated at engine speeds above 5000 rpm when the transmission is in overdrive This over speed condition will cause damage to the bearings and geartrain in the RubiCrawler in addition to possible damage to other components in the vehicle RUBICRAWLER INFORMATION 47 ATLAS REBUILDS AND REPLACEMENT ITEMS Seal and bearing kits AB 1000 and AB1001 are complete rebuild kits that include new seals bearings gaskets synchro dogs springs and brass rings The AB1000 is for Atlas transfer cases that have the 32 spline front output and the AB1001 is for the 26 spline front output units The 4 speed Atlas could use the AB1000 with the addition of a few additional bearings that we use in the reduction housing S
88. should be inspected to verify that all fasteners and components relating to the transfer case are properly attached A visual inspection should be made with regard to driveline angles and clearance New and unwanted noises are most often related to poor driveshaft angles C V driveshaft combinations must be set so that the differential yokes are in line with the driveshaft under normal operating load Non C V driveshaft combinations must be set so that the pinion yoke angles match the transfer case output yoke angles under normal operating load Remember to allow for spring wrap if you have leaf springs The front pinion will dive downward under load and the rear pinion will rise upward There are many different spring rates on the market so this may take some tweaking to eliminate a poor driveshaft condition For examples see photos below The Atlas transfer case is a close tolerance design If you feel any vibration at all in the shift handles suspect improper driveshaft angles Rear too low Will not raise enough for C V Rear correct Perfect for C V FINAL INSTALLATION OIL AND INSPECTION 39 40 OPERATING YOUR NEW ATLAS The Atlas has internal shifter interlocks that prevent the unit from being mis shifted The knobs on the Atlas Twin Stick are to assist you with identifying the rear output and the front output For 2WD High in which the vehicle should first be tested the knob labeled Rear will be in the
89. siderations ee 41 Divorced Atlas Lote asc Li iS sss E DEL RU OE EE 20 Atlas 2 amp 4 Speed Dimensions cccc 42 Toyota Tacoma Tundra and TIOO sss 21 Atlas Design Updates 1 mee 43 Nissan Titan Frontier amp Xterra ssseee 21 RubiCrawler Information eee 44 47 LIMITED WARRANTY Atlas transfer cases are guaranteed against defects in workmanship and materials for the life of the original purchaser and is non transferable This lifetime guarantee covers and is limited to gear sets and castings The remainder of the unit i e shafts bearings gaskets hardware is covered by our limited 1 year warranty This warranty begins from the date the unit is shipped from Advance Adapters The warranties are voided as determined by Advance Adapters Inc by misuse abuse improper maintenance or alterations of the product These guarantees DO NOT cover any labor shipping normal wear or any other unforeseen event that may occur due to failure of a unit Advance Adapters reserves the right to repair or replace any product All returns must be sent prepaid and have a Return Authorization Number RGA Please call the sales department for assistance WARRANTY IS VOID if the proper gear lubricants are not used and proper oil levels are not kept and or the product has not been properly installed and instructions have not been followed SPECIAL NOTE T
90. ted on a Jeep TJ right 4 SPEED SHIFTER OPTIONS 33 34 COMMON INSTALLATI N MISTAKES This section highlights a few of the areas that we commonly see mistakes made during the installation ofan Atlas 2 and 4 speed These mistakes will cost you time and money Most problems occur because the installation is rushed or procedures overlooked Other errors happen because the instructions were not read or followed The most common mistake is having a transmission output shaft that is too long or does not have long enough splines A shaft that has either one of these problems can bottom out or not engage enough into the Atlas input Most times this interference 1s not noticed until the transfer case is being installed Most installers get the transfer case near to the mating flange but find they are lacking roughly 1 16 of an inch between the two gear boxes com ing together They push pull amp rotate to mate the two boxes then decide to put the nuts on the stud of the transfer case to pull the units together The transfer case whether being a 2 speed or 4 speed is now damaged the 2 speed having a broken front housing snap ring and the cage needle bearing of the 4 speed having been pre loaded Running the units in this state will cause complete destruction of the unit In short both units will need disassembly to fix the problem The easiest fix 1s prevention Ifthe gear boxes do not slide together completely when installing remove th
91. the output spline to a 23 spline See the 23 Spline section This kit also incorporates a reluctor ring and sensor for proper transmission operation 4L60E 4WD w Removable BHSG When obtaining a 4L60E out of a 4WD vehicle the output shaft stickout length should be 4 438 from the rear hex bolt flange of the transmission We offer P N 50 0405E which adapts the hex bolt pattern to a square bolt pattern This adapter also provides a reluctor sensor and clamp on reluctor ring Adapter housing P N AS 9111 2 5 long can be purchased from us to use this transmission with the stock 27 spline 4WD output shaft 4L60E 2WD w Removable BHSG When obtaining a 4L60E out of a 2WD vehicle the stock output shaft will be too long To use this transmission you will be required to use P N 50 0405 fits 700R shaft or P N 50 0405E fits 4L60E shaft which adapts the hex bolt pattern to a square bolt pattern This adapter also provides a reluctor sensor and clamp on reluctor ring To couple this tranny to the Atlas transfer case you will then need adapter P N 50 9102 1 5 long This kit requires the installation of a new output shaft switching the output shaft spline to a 23 spline See the 23 Spline section SHORTY 4L60E ADAPTER w Removable for the ATLAS 2 Speed We are proud to offer the shortest overdrive automatic transmission and transfer case combination on the market today Our kit P N 50 9300 is designed for the late model 4L60E transmission with a removabl
92. tic transmission the shifting procedure should be to stop the vehicle Shift the transmission to neutral and then quickly shift the planetary If you pause the transmission output shaft will accelerate while the planetary is between gears If the shift is not immediately successful then shut off the engine while the transmission is still in neutral Once the engine is shut off complete the shift of the planetary unit Restart your engine while the transmission is still in neutral Cable Shifter This shifter provides a linkage system that can be mounted to the floorboard of the vehicle This single handle shifter has a front to rear movement and only requires a small clearance hole in the floorboard It requires you to route the cable so that it does not interfere with the driveshafts or other moving components We also recommend that you keep the cable away from the exhaust as much as possible The location of the shifter on the floorboard can vary On Jeeps with a full console like the TJs we have found that this shifter fits nicely besides the emergency brake towards the driver s seat We ve also had customers install the shifter between the driver s door and their seat The floorboard requires three holes drilled through and a small oval slot for the handle P N 344020 Cable Shifter Atlas 4 speed d or Jeep TJ without a console Jeep TJ 4 speed shifter located between the E brake and the console left and the 4 speed cable rou
93. tlas Bolt Torque Specifications COMPONENT FASTENER DESCRIPTION ar BOLT SEALANT THREADLOCK WASHER TORQUE SPEC Fi Lbs N m HOUSING OIL PAN BLIND 5 16 18X1 FHCS RTV SILICONE HOUSING OIL PAN THRU 5 16 18X1 FHCS RTV SILICONE HOUSING OIL PAN DIVORCED 5 1 18X1 1 4 FHCS HOUSING INPUT MARRIED DIVORCED 3 8 16X1 1 4 SHCS 6 IRIVSIICONE Y jos HOUSING DIVORCED INPUT 3 8 16X1 1 4 SHCS amp MED STRENGTH THREADLOCK HOUSING REAR OUTPUT HOUSING FRONT OUTPUT HOUSING SHIFT RAIL 3 8 16X1 1 4 SHCS 5 RTV SILICONE HOUSING SHIFT RAIL 3 8 16X1 3 4 SHCS RTV SILICONE HOUSING SHIFTER SUPPORT 3 8 16X1 1 4 SHCS RTV SILICONE HOUSING FRONT BRG CAP CY L1 env sue 3 8 16X1 1 4 SHCS 5 RTV SILICONE 35 48 3D 4 30 4 5 16 18X1 FHCS RTV SILICONE BRACKET DIVORCED MOUNT PAN 5 16 18X1 1 4FHCS 10 RTV SILICONE BRACKET DIVORCED MOUNT INPUT 3 8 l amp X1 1 4SHCS amp MED STRENGTH THREADLOCK SHAFI CLUSTER RETAINER SPEEDO 5 16 16X3 4HHCS 30606 N fo 1 4 NPT FITING BREATHER SO DEGREEW 8 NPT JRIVSIICONE N fo PLUG OILPAN J s i amp 18W MAG 1 SEALWASHR Y hon PLUG SHIFT HOUSING SWITCH BORE SEAL WASHER 12 16 3 8 24X1 2 CPSS MED STRENGTH THREADLOCK Mur Yox z amp m resme 1 SASH Y one NUT YOKE 32SPL el E20 INT FIT 170indbs 1 SEAL WASHER 50 204 FRONT INPUT SHAFTS Toyota Tacoma Tundra and 11
94. to assist you in this manner The newest Jeep that used a New Process 241 transfer case picked up the speed from the axles and the speedometer hole in the Atlas can be plugged On engine converted vehicles caution should be used If your engine has been converted to a newer Chevy Ford or Chrysler and is computer controlled it may also require a vehicle speed sensor The speed sensor is usually connected at the speedometer Each manufacturer has designed their own unique way of obtaining this computer input If your vehicle has any computer requirements you will need to take this into consideration If you are wanting to install the Atlas into a Chevy Ford or Chrysler vehicle the computer requirements mentioned will also apply Once you ve taken into consideration your specific requirements the speedometer cable can now be connected Note Listed in the Tailhousing Options section on Pages 24 25 are a few of the VSS output components we offer Speedometer Calibration There are two factors that affect your speedometer reading actual tire diameter and axle gear ratio The actual tire diameter is usually different than what is printed on the side wall of your tire For example A33x 11 5 x 15 tire depending on the brand may actually measure 32 5 in diameter Tire sizes vary greatly among the manufacturers Even the same tire from the same manufacturer can vary as much as 7 in diameter The speedometer charts on Pages 28 29 will assist you i
95. unt These cases would use a STD 23 spline input FRONT INPUT SHAFTS JEEP amp DODGE 42RLE TRANSMISSION This automatic overdrive transmission was used in Jeep Wranglers from 2003 through 2011 in both the Jeep TJ amp JK and Dodge Dakotas 2004 2009 Both the 2 speed and 4 speed Atlas transfer cases use the short 23 spline input JEEP 2012 JK AUTO AND MANUAL TRANSMISSIONS This automatic overdrive transmission is used in Jeep JKs from 2012 and newer The Atlas 2 speed uses a new male 26 spline flanged shaft to couple to the A580 transmission Starting in 2012 Jeeps with a manual transmission stayed with NSG 370 which is a short 23 spline female see information below The Atlas 4 speed is not an option on the automatic transmission due to the computer programming issues on the Jeep drivetrain See Page 30 JEEP 45RFE TRANSMISSION The 45RFE transmission was used in 1999 to 2004 WJ Grand Cherokees with the 4 7 V8 and a NP247 transfer case This transmission was also used in 2002 amp newer Dodge Durango and Dakotas with a 4 7 V8 This transmission had a 1 recessed output shaft from the rear of the transmission We offer the Atlas transfer case with a longer 23 spline input shaft to couple to the 45RFE shorter transmission shaft length ADDITIONAL 23 SPLINE TRANSMISSIONS The transmission output shaft length or Atlas input shaft length cannot be determined by transmission model only The following are some transmission models that may diffe
96. urface There should not be any GAP between the two units If they do not meet then you have an interference problem Refer to the Atlas Input Shaft section for the recommended transmission shaft lengths DO NOT PULL THE TWO UNITS TOGETHER WITH THE FASTENERS This will cause internal damage to the unit Possible problems may be too long of an output shaft or on some Jeep 21 amp 23 spline transmissions a spacer adapter may be necessary If you are in doubt regarding your interference problem please call The recommended nuts have been provided to secure the Atlas to your adapter With the Atlas now secure check again for proper clearances such as driveshaft floorboard skid pan and exhaust etc DRIVELINE MODIFICATIONS You will normally need driveline modifications when installing the Atlas transfer case What we have found that works well is either adding or subtracting depending on the application the measurements of the Atlas from the stock length of your transfer case REAR MEASUREMENT To determine the new length for the rear driveline simply measure from the face of the transfer case to the face of the rear output yoke Fig C Write that measurement down Take the same type of measurement of the Atlas With that in mind consider the following example Rear Measurement Example Fig C This stock transfer case mea sured on our example 16 8 When subtracting that measurement from the Atlas measurement of 13 8 you have a di
97. veline as recommended in the Preparation section You would now have your front driveshaft length FINAL INSTALLATION DRIVELINE MODS 3 BREATHER INSTALLATION The stock transfer case breather hose should be replaced with a 3 8 fuel hose and connected to the brass elbow located on top of the Atlas A new breather should be installed on the opposite end of this hose and mounted to the firewall A free flowing p e atmospheric breather typically found in earlier model vehicles or used on differentials v 1 is best On later model Jeeps the stock breather is very restrictive This stock breather is for lighter viscosity oils such as the ATF used in the stock transfer case If this breather is not replaced oil will blow out into the engine compartment We offer new breather kits listed on Page 4 SPEEDOMETER INSTALLATION We can supply a cable type speedometer drive unit for all applications other than Jeeps 1982 to current The 1982 and newer Jeeps will use the original soeedometer drive that came stock You will simply have to remove it from your New Process transfer case and install it into your new Atlas It is recommended that you replace the o ring and seal that we have included with the Atlas package On older Broncos Bronco Ils Explorers and Rangers a speedometer cable fitting adapter must used to connect the Atlas speedometer drive to your speedometer cable Nevada Speedometer Ph 775 358 7422 should have the necessary parts
98. ving the triangular 3 bolt base on the unit The Atlas must be installed into the vehicle EP without the shifters attached On Atlas 4 speed units the cable shifter on the reduction housing must be installed before installing the Atlas into your vehicle HEAT SHRINK SLEEVE ALL THREAD p osa E m NYLINER BRG INSTALL UNTIL TIGHT THEN TURN BACK JUST ENOUGH TO ALIGN EXTENSION TUBE SHIFT TOWER BUTTONS INSTALLATION PROCEDURES 35 36 A normal installation of the Atlas transfer case should take around 6 to 8 hours Before disassembling your vehicle the undercarriage should be cleaned to aid in the installation process Stock driveline lengths should be EPOR measured with your vehicle on the ground The measurement should be taken as illustrated on Fig B Retain these a measurements for later use The Atlas offers up to 4 different rotations de pending on the application We offer the same Fig B I rotation as stock on all units The other rotations amp rear or are provided for either additional ground clearance D or unique applications Vehicles using one of our adapters with the dual bolt patterns have 8 rotation options Before removing your stock transfer case an angle finder can be used to obtain the rotation of your stock transfer case Your vehicle can now be raised for the necessary removal of the driveshafts skid pan and the stock transfer case Note Please make sure your vehicle is

Atlas manual 2013.p65

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