User Manual

ADVANCE ADAPTERS INC. P/N: 50-6404
P.O. Box 247, 4320 Aerotech Center Way Old Part No: 711064
Paso Robles, CA 93447 PAGE 2 OF 3
Telephone: [phone] Fax: [phone] Page Rev. Date: 02-25-02
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.
When assembling the adapter housing to the transmission case, we have provided you with a new gasket to prevent fluid
leakage. This gasket is a stock GM item that is used on all TH400 installations. The seal in the Dana 300 bearing retainer
will prevent fluid from mixing between the transmission and transfer case. A new seal has been provided and should be
installed with the open side towards the automatic transmission. We have also included a new sealed bearing that will
replace the original Dana 300 bearing. This new sealed bearing will give added protection.
All installations will require the use of a transmission cooler. The cooler can be either installed in the radiator or a remote
location is acceptable. The transmission shift control can either be a Hurst floor mounted type shifter or sometimes the
existing column shift can be modified on certain applications.
The adapter thickness is 4-3/8" and will normally require the transfer case to be relocated on most conversions. Kit No.
50-6402 uses a thinner adapter plate that is only 1-1/4" thick and can be installed in Jeep Wranglers only. The kit is available
in both the 21 & 23 spline TH400 output shaft.
INSTALLATION:
1. Starting at the Dana 300 transfer case, remove the 6 socket head bolts from the aluminum index hub on the front
side the transfer case.
2. Using the two slots on the side of this retainer, you will need to pry the retainer out of the transfer case. This retainer
assembly does pilot into the rear output shaft of this transfer case, if the retainer assembly seams tight to remove
try spinning the rear output shaft.
3. Once the retainer is removed you will need a pair of snap ring pliers to remove the snap ring that retains the drive
gear to the input shaft. Remove the snap ring and the drive gear from the input shaft. The aluminum retainer should
now have the bearing, input shaft, seal and a snap ring holding the bearing into the retainer. This snap ring must also
be removed to allow the bearing and input shaft to be pressed out of the index housing.
4. The seal will also require to be pressed out of the index retainer. The retainer should now be empty.
5. Install the new bearing onto the new input shaft, install both components into the stock retainer and install the stock
snap ring.
6. Install the input drive gear onto the input shaft and retain it with the stock snap ring. Make sure the gear is installed
so that the cogged side of the gear is facing away from the bearing.
7. Install the new seal provided in the kit. The open side towards the transmission.
8. Apply Loctite 515 or equivalent sealant to the retainer surface and install into the Dana 300 transfer case. Make
sure the pocket bearing is installed in the Dana 300 output shaft.
9. Bolt retainer to transfer case using the stock bolts. Torque to 10 ft./lbs.
10. This kit fits the TH400 2WD transmission only. The stock 2WD output shaft must be shortened to a stickout of 3.750"
from the rear of the transmission.
11. Install the adapter to the TH400 using the 3/8"-16 x 1 1/4" bolts and lock washers, make sure you install the gasket
between the adapter and the transmission.
12. The transfer case should be test fitted to the adapter and to check shaft engagement. Make sure the transfer case
fits flush up to the adapter surface. If not check for burrs on the shafts and or output shaft cut off length. Never
pull the transfer case to the adapter using the bolts to draw these components together. The adapter also provides
an option of two rotation angles for the transfer case (stock rotation is 35 degrees).
GM 2WD 32T TH400 AUTOMATIC TO
JEEP DANA 300 TRANSFER CASE