ADVANCE ADAPTERS INC. P/N: ATLAS ATLAS TRANSFER CASE
Contents
1. 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 assembly and the additional needle bearings will occur THINGS YOU SHOULD KNOW ABOUT YOUR ATLAS DO NOT disassemble the unit Disassembly of the unit will void your warranty 2 We have had a few customers that have disassembled their Atlas transfer case One mistake commonly made is the reassembly of the unit The tailhousing on the Atlas is a component that must be shimmed properly in order for the unit to operate properly When reinstalling the tailhousing most individuals use a silicone sealant which changes the end play on the Atlas and will cause internal problems Proper support of the Atlas and transmission with a support mount that is in good shape is recommended Check the yoke nut torque specifications periodically The yoke nuts should be torqued at 150 ft Ibs It is twice as hard to shift the transfer case if the vehicle is not at least slowly rolling forward In addition trying to shift the transfer case while the wheels are turned puts a bind on the synchronizers making it almost impossible to shift in or out of gear 6 Layout and inventory all parts Test fit before starting the installation2. Verify the configuration of your Atlas 7 Give ample clearance between the Atlas and the body The shifters also need to have complete free range of motion 8 We have found that driveline angles are responsible for 99 9 of all noises that seem to be coming from the Atlas a aS page 8 Q r at Ing Your NewAt as 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 willbe inthe 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
3. ZF 6SP S6 650 TRANS 29 SHORTY C4 FORD TRANS 50 2903 2905 27 TACOMA TRANS 23 SPLINE 50 5710 23 short ALLISON 1000 TRANS SEE PAGE 14 29 TACOMA TRANS 26 SPLINE 50 5711 23 short FORD AOD EARLY 49 4WD STOCK 1 5 7 31 POW ERGLIDE automatic 50 9200 27 1987 amp EARLIER 2WDTRANS 50 2902 3 7 23 Toyota Crawler Box FORD AODLATE4SP 4WD STOCK 1 5 7 31 to Atlas Case 50 5915 23 1988 amp UP 2WD TRANS 50 2901 3 7 23 2012 amp Newer JEEP STOCK 26 FORD C6 3 SP TRANS STOCK 1 5 7 31 AUTOMATICS 20 CASE LENGTH 2012 amp Newer J EEP STOCK 23 FORD eExpPLORER RANGER BRONCO II STOCK 5 25 Manuals 1980 11 J EEP AUTOMATICS STOCK 1 5 210r23 THIS KIT USES A SPUD SHAFT USES A STOCK 2WD OUTPUT SHAFT UP TO THE TRANSMISSION ADAPTER 3 5 THIS KIT SHOULD BE USED IN CONJUNCTION WITHA 700R KIT THE CASTING IN THIS KIT ONLY HAS ONE ROTATION AVAILABLE THIS TRANSMISSION IF CURRENTLY ADAPTED TOA BRONCO DANA 20 TRANSFER CASE CAN USE AN ATLAS 28 SPLINE TRANSFER CASE AS A DIRECT BOLT 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 BACK SIDE OF THE ADAPTER HOUSING 10 ARELUCTOR RING AND SENSOR KIT MUST BE PURCHASED P N 716073 OUTPUT SHAFT MAY NEED TO BE SHORTENED OR A SPACER ADAPTER MAY NEED TO BE USED AS 0404 1 AS 8603 3 4 AS 8610 1 2 page 2 Inst al at ion Procedures For A Vehicl es Before the actual installation begins you sh
4. 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 If the 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 is 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 been 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
5. 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 experience 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 s
6. 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 chart below will assist you in obtaining the right soeedometer 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 Snort Electronictype 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 We offer many stock gear options for your soeedometer housing Le When installing a speedometer gear 5 38 5 13 4 88 4 56 4 10 3 73 3 55 3 07 with either 39 40 41 or 42 teeth the 44 33T 30T 30T 28T gear and the housing must be installed separately These are all large diam Long Cable type 42 SOT 33T 31T 29T eter soeedometer gears By first in m 36T SOT 33T SIT 28T stalling the gear into the tailhousing n 37T 36T 34T 32T 281 261 you will be able to tilt the gear shaft up 38 38T 36T 35T 32T 29T 2 1 allowing you to position the gear past 37 39T 37T 36T 33T 30T 2 1 26T the Atlas output shaft Once this gear 36 40T 39T 37T 34T 31
7. 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 inter ference is 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 coming 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 is prevention If the gear boxes do not slide together completely when installing remove the 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
8. of the Atlas from the stock length of your transfer case REAR MEASUREMENT To determine the new length forthe 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 difference 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 MEASUREMENT 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 measure ment protrudes out from the adapter input face or a negative measurement 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 fr
9. on the application We offer the same T rotation as stock on all units The other rotations rear oe are provided for either additional ground clearance a 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 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 is also 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 output isn t too 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 adap
10. the best possible performance lf 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 CONSIDERAT ONS Brakes On flat 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 If 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 TOMNG The ATLAS 2 speed has
11. 00 4WD TRANS AS6401 amp 32 11 87 CASE LENGTH 3 25 ADAP SHAFT STICKOUT OF 2 5 NOTE 9 AS 0404 5 JEEPT18 4 SPEED 50 7502 3 7 23 GM 4L80 amp 4L80E 4SP TRANS 51 6408 32 11 87 CASE LENGTH 3 25 ADAP USE GM 4WD SHAFT NOTE 9 5 FORD T18 4 SPEED 50 7500 3 8 7 23 GM 700R 4L60 O D 4 SPEED 50 9102 3 23 11 87 CASE LENGTH 3 25 ADAP 23 375 CASE LENGTH 2W D TRANS FORD T19 4 SPEED 52 6501 3 8 7 27 GM 700R 4L60 O D 4 SPEED AS9111 27 11 87 CASE LENGTH 51 7500 23 375 CASE 4W D TRANS 5 FORD NP435 4 SPEED 50 3801 3 8 7 23 GM 4L60E 2WD amp 4WD 50 0404 3 23 10 87 CASE LENGTH 4 25 ADAP 23 375 CASE LENGTH 1980 to 1986 STOCK STOCK 23 GM 4L60E 4WD TRANS AS9111 27 J EEP TRANSMISSIONS ADAPTER 23 375 CASE LENGTH 5 10 1987 amp NEWER STOCK STOCK 7 210R23 GM4L60E2WD 50 0405 amp E 23 J EEP TRANS 21 SPL OR 23 SPL ADAPTER W REMOVABLE BELLHOUSING 50 9102 3 GM NV4500 4WD 32 SPL 51 0205 5 32 GM 4L60E 4WD TRANS 50 0405 amp E 27 12 375 CASE LENGTH 51 0220 W REMOVABLE BELLHOUSING AS9111 DODGE NV4500 4WD 23 SPL STOCK 5 7 23 GM 4L60E 4WD TRANS sHorty 50 9300 3 23 12 375 CASE LENGTH 6 3 ADAPTER W REMOVABLE BELLHOUSING 50 9305 3 DODGE NV4500 4WD 29 SPL STOCK 65 7 29 GM 6L80 6L90 50 9600 32 0r 29 6 3 ADAPTER 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 8100 3 23 10 CASE LENGTH ALL OTHER VEHICLES GM
12. ADVANCE ADAPTERS INC P N ATLAS P O Box 247 4320 Aerotech Center Way Paso Robles CA 93447 PAGE 1 OF 11 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 21 15 ATLAS TRANSFER CASE THIS UNIT IS SHIPPED DRY All open holes are plugged on the new Atlas case with red plastic caps only to keep contaminates out When unpacking inspect for any lost or damaged items during shipping All Atlas transfer cases are hand built to your predetermined specifications Please verify that ALL features such as input spline and case configurations left or right hand drop are correct We have included a application chart on the next page for your reference If changing a yoke or checking your yoke options see the last page of this instructions Amsoil is the recommened oil for the Atlas 2 amp 4 speed units We offer several billet aluminum i shifter knobs in 5 colors i We offer an Atlas installation kit for the 2 and 4 speed transfer cases Which includes a new vent hose vent and oil for the first oil change Theunversd crivetran jak GREAT KRALS INSTALLATIONS This new patented drivetrain jack is for anybody that works on their own vehicles as well as shop owners and mechanics The Uni Raise allows you to remove the stock skid pan and or crossmember while it supports the drivetrain The Uni Raise is versatile enough for the avid four wheeler to do on the spot trail repairs safe amp simple as well as the shop mechanic
13. T 28T 271 is in place the speedometer housing 35 42T 40T 38T 25T 29T 20T 28T must be aligned with the speedom 33 43T 40T 37T 34T 31T 29T eter gear shaft and indexed into the 32 41T 39T 35T 20T 30T 26T tailhousing oo ert the 31 aT 40T 3T 33T 3T 27TH Contacts the Atlas tallhousing wit 30 HT S7T AT I T abit of oil This will prevent the o ring cal 431 38T 35T 33T 291 from being nicked upon installation or 28 40T 36T 34T 30T rotation causing this housing to leak page 6 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 soeedometer housing can be rotated to achieve proper contact Note There are three rotation possibilities Many of the Jeep soeedometer housings offer index numbers that reference to the gear tooth count By lining up the retainer clip with the proper index number the soeedometer gear will work properly If your housing does not have these index numbers proper engagement can be obtained by rotating the soeedometer housing until the soeedometer 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 1 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
14. b 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 conditions The only shift position that is not available is Front 2WD high 4 Speed Atlas Reduction Housing This is anon synchronized shifted unit To shift the 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 page 9 Q r at Ing Consider at ions 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
15. cle is back on the ground the transfer case area 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 CMAN Inst al at ion MSTAKES This section highlights a few of the areas that we commonly see mistakes made during the installation of an 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
16. 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 synchronized 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 M anual transmission While the vehicle is slowly moving forward depress the clutch and engage the front or rear control into Low DO NOT 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 SHFT POSITIONS N eutral Both the rear and front Knobs in the N position 2WD High The rear Knob in H position and the front kno
17. for his daily work The Uni Raise is adjustable to different frame widths and capable of supporting 600 pounds Rather than using a floor jack to support your drivetrain making it impossible to move the vehicle around if needed the Uni Raise supports the drivetrain from the frame rails allowing you to move the vehicle without having to reinstall the crossmember for support The Uni Raise can be installed in minutes Just adjust the unit to your frame width connect the hooks to your frame and center the jack under the transmission or rear of the engine SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores At as Adag er Sel ect ion Qart 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 applicat
18. from the shift control and then rotate the assembly back into position for the soeedometer gear engagement The other option is to keep the white portion of the speedometer rotated 180 degrees from where 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 CROSSMEVIBRR 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 VISUALI NSPECTION Once the vehi
19. hould 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 page 10 Yoke Qt ions And Int er changeabl e Yokes era 1310 series C V 1330 series CV B10 series non CV 1350 series non C V NAT 472015 1350 series CV 1410 series non C V Straps 1410 series non C V U bolt P N A1410U P N 300488 P N 300473 Flange Yokes 325pm _ T1 T Z 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 N 300473 NAT 472015 1410 Flange yoke is drilled and tapped for 4 12mm x 1 25 bolts on a3 75 diameter and has a 2 75 female index for the mating yoke The 1300 series flange yoke is shown below 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 1310C V P N 211229x 1310 non C V P N 2 2 9389 1330 C V P N 211631x 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 Yoke Modifications Changing the style of yokes on the Atlas transfer case
20. ions 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 ATLAS TRANSFER CASE apapter kit attasinpeut ATLAS TRANSFER CASE ADAPTER KIT ATLASINPUT ADAPTER SELECTION ADAPTER SPLINE ADAPTER SELECTION ADAPTER SPLINE CHART FOR GM FORD HOUSING CHART FOR GM FORD HOUSING JEEP amp DODGE OR JEEP amp DODGE OR MANUAL amp AUTO STOCK HOUSING AUTOMATIC STOCK HOUSING TRANSMISSIONS TRANSMISSIONS GM SM420 4 SPEED 50 9702 2 23 GM TH350 2WD TRANS 2 10 5 CASE LENGTH 5 25 ADAP 21 5 CASE LENGTH 50 6802 3 23 GM SM465 4WD 10 SPL 51 9807 7 10 GM TH350 4WD TRANS 50 6304 2 23 12 CASE LENGTH 3 5 ADAPTER 21 5 CASE LENGTH AS6800 5 27 GM SM465 2WD 35 SPL 51 9807 4 7 35 GM TH400 2WD TRANS 51 6400 4 32 12 CASE LENGTH NOTE 9 3 5 ADAPTER SHAFT STICKOUT OF 5 NOTE 9 FORD T amp C4 SPEED O D STOCK 5 8 31 OR28 GMTH400 4WD TRANS AS 6401 5 32 10 25 CASE LENGTH 4WD trans SHAFT STICKOUT OF 1 5 NOTE 9 FORD amp J EEP T98 4 SPEED 50 7503 3 7 23 GM TH4
21. it to vent the extra oil out the breather PREPARATION Now is a good time to familiarize yourself with the shifter l components Pre assembly of the shifter items will help a great deal with the final installation Unpack the shifter and install Sa 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 leaving the triangular 3 bolt base on the unit The Atlas must be installed into the vehicle 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 pees NYLINER BRG p ES eh INSTALL UNTIL TIGHT THEN TURN N m BACK JUST ENOUGH TO ALIGN Q a EXTENSION TUBE SHIFT TOWER BUTTONS page 3 Anormal 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 une installation process Stock driveline lengths should be measured with your vehicle on the ground The measurement should be taken as illustrated on Fig B Retain these measurements for T C OUTPUT Pe Se later use a ee The Atlas offers up to 4 different rotations de Fig B N pending
22. 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 below shows the required machining on these yokes 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 lbs 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 150 155 ft lbs UJ oint s Spicer D Dia E width Part Std Spicer series of cap in across caps in non C V U bolt Part 1310 1 062 3 219 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 7 16 20 THRU 4 PLCS EQ SP 03 500 B C 1 2 20 THRU 4 PLCS EQ SP 4 250 B C e4 am S lt k page 11
23. ont yoke to the transmission adapter input Fig D Front Measurement Example Fig D This stock transfer case Our Stock driveshaft top vs new fixed yoke driveshafts 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 this distance This difference can now be page 5 BREATHERINSTALLATION 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 atmospheric breather typically found in earlier model vehicles or used on differentials 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 for the 2 and 4 speed cases SPEEDOMETER NSTALLATI ON We can supply a cable type soeedometer 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 ne
24. or example Shift indicator switch soeedometer site tube and drain plug etc The Atlas is also shipped with numerous red plastic caps to keep contaminates out of the unit Atthis pointin time remove all caps and properly install all components page 4 The Final Inst al ation 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 surface 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 MOD A CATIONS 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
25. ould 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 LUBRICATION 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 Any 75 90w synthetic GL 4 rated oil will work On the Atlas HD applications we are now recommending Amsoil SAE 190 The recommended oil capacity is 2 quarts in the Atlas 2 speed 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 i level Therefore we have supplied your unit with a site tube to aid in determiningthe a f s n correct fluid level Once the required two quarts are put into the Atlas we rs recommend marking the oil level on the site tube We like to use a small zip tie a oil level marking device Note When the Atlas is overfilled beyond the recommended levels it will cause the un
26. ter 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 inthis new rotation Note On many ofthe 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 modifications 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 STUDSINTOTHEATLASINPUT RING TIP Before the final bolt up we have found it easier to equip the Atlas with all the necessary components F
27. w Atlas It is recommended that you replace the o ring and seal that we have included with the Atlas package On older Broncos Bronco IIs Explorers and Rangers a speedometer cable fitting adapter must used to connect the Atlas soeedometer drive to your soeedometer cable Nevada Speedometer Ph 775 358 7422 should have the necessary parts 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 soeed sensor The speed sensor is usually connected at the soeedometer 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 soeedometer cable can now be connected Speedometer Calibration There are two factors that affect your soeedometer 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 A33 x 11 5 x 15 tire depending on the brand
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