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P/N AB1000 32sp front output

Qty Part No. Description

ADVANCE ADAPTERS, INC.

4320 Aerotech Center Way, Paso Robles, CA 93446

ASSEMBLY INSTRUCTION SHEET

Page 1 of 12 Rev. Date: 07-14-10 P/N AB1000 & AB1001

P/N AB1001 26sp front output

Qty Part No. Description

ATLAS 2 SPEED REBUILD KITS

NOTE: We have not included the 32 spline yoke seals in these kits due to the two yoke diameters. These seals

must be ordered separtly. The caged bearing that fit the in the rear output shaft is not included in this kit, it is a

low wear bearing and is very difficult to remove.

1 300314 REAR OUTPUT BEARING

2 300355 CLUSTER THRUST WASHERS

2 300358 O-RING CLUSTER SHAFT

4 300370 BRAS SYNCRO RINGS

6 300372 SYNCRO DOGS

4 300373 SYNCRO DOR SPRINGSS

4 300383 SHIFT FORK PADS

2 300386 SET SCREW FOR SHIFT FORK

2 300387 SEAL FOR SHIFT RAIL

1 300393 FRONT OUTPUT THRUST WASHER

2 300474 RUBBER SEAL YOKE WASHER

2 300476 YOKE NUTS

3 300490 O-RING FOR INPUT AND OUTPUTS

6 300491 TAILHOUSING BEARING SHIMS

1 300499 FRONT INPUT SEAL

1 300500 FRONT INPUT SEAL

1 300509 FRONT OUTPUT THRUST WASHER

1 300510 FRONT INPUT BEARING

1 300511 FRONT OUTPUT BEARING

1 300512 FRONT OUTPUT BEARING

2 300513 REAR OUTPUT BEARING

1 300514 REAR OUTPUT BEARING

1 300515 OUTPUT SHAFT POCKET BEARING

2 300516 CLUSTER GEAR BEARINGS

2 300517 HIGH GEAR BEARINGS

2 300518 LOW SPEED GEAR BEARINGS

1 300919 DRAIN PLUG SEAL WASHER

1 301400 PAN GASKET

1 716453 SNAP RING

1 716455 SNAP RING

6 300105S FRONT HOUSING BEARING SHIMS

1 300314 REAR OUTPUT BEARING

2 300355 CLUSTER THRUST WASHERS

2 300358 O-RING CLUSTER SHAFT

4 300370 BRAS SYNCRO RINGS

6 300372 SYNCRO DOGS

4 300373 SYNCRO DOR SPRINGSS

4 300383 SHIFT FORK PADS

2 300386 SET SCREW FOR SHIFT FORK

2 300387 SEAL FOR SHIFT RAIL

1 300474 RUBBER SEAL YOKE WASHER

1 300476 YOKE NUTS

1 300478 FRONT YOKE NUT

1 300480 FRONT YOKE SEAL WASHER

3 300490 O-RING FOR INPUT AND OUTPUTS

6 300491 TAILHOUSING BEARING SHIMS

1 300499 FRONT INPUT SEAL

1 300500 FRONT INPUT SEAL

1 300501 FRONT OUTPUT SEAL

2 300509 FRONT OUTPUT THRUST WASHER

1 300510 FRONT INPUT BEARING

2 300511 FRONT OUTPUT BEARING

2 300512 FRONT OUTPUT BEARING

1 300513 REAR OUTPUT BEARING

1 300514 REAR OUTPUT BEARING

1 300515 OUTPUT SHAFT POCKET BEARING

2 300516 CLUSTER GEAR BEARINGS

2 300517 HIGH GEAR BEARINGS

2 300518 LOW SPEED GEAR BEARINGS

1 300919 DRAIN PLUG SEAL WASHER

1 301400 PAN GASKET

1 716453 SNAP RING

1 716455 SNAP RING

6 300105S FRONT HOUSING BEARING SHIMS

Summary of content (12 pages)

PAGE 1
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 1 of 12 Rev. Date: 07-14-10 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS P/N AB1000 32sp front output P/N AB1001 26sp front output Qty Qty 1 2 2 4 6 4 4 2 2 1 2 2 3 6 1 1 1 1 1 1 2 1 1 2 2 2 1 1 1 1 6 Part No.
PAGE 2
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 2 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Remove the transfer case from the vehicle. Remove the drain plug and the drain oil. Remove (14) torx head bolts and remove the inspection cover. Clean the surface of any debris. Remove the cluster pin retaining the bolts. Remove the cluster pin from the unit. Remove the cluster gear.
PAGE 3
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 3 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Using a plastic dead blow hammer, use one hand to support the Atlas shift forks inside the case to prevent binding on the shift rails and the other hand on the hammer, lightly tapping the shift rails from the front of the case. This provides an easy way of pulling the shifter control from the Atlas case.
PAGE 4
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 4 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Next, remove the shifter slider, the synchronizer springs, the synchronizer dogs and the brass rings. Turn the case so that you are looking at the input ring. Remove the six bolts that hold it to the case. Use your dead blow hammer to firmly hit the side of the transfer case while pulling on the input shaft.
PAGE 5
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 5 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS it over the hub. Press it down firmly so that it gets "stuck" and holds in place. Position the gear into the case. The synchro ring side should be facing the front of the T/C. With a small amount of oil, lubricate the appropriate caged needle bearing and slid it into the pancake gear.
PAGE 6
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 6 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Without disturbing the synchro assembly, guide the output shaft through the front of the case, and through the pancake gear. Pay attention to the caged needle bearing inside the pancake. It will get pushed out slightly, so you will need to take your other hand and guide it through.
PAGE 7
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 7 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Next to go on is the roller tapered bearing (the larger of the two new bearings). Preferably, it needs to be pushed on by hand. Please put adequate pressure on the output shaft so it does not slip out of the synchro dog grooves.
PAGE 8
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 8 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Assembly reminder: Hold the output shaft in your hand. You want to have the three notches over you thumb and fore finger. Slip the slider over the shaft and drop in the three synchro dogs. Roll the spring onto the two of the dogs and then snap it into the third and flip shaft over and repeat this step.
PAGE 9
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 9 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Take the tappered roller bearing race and tap the rear race flush with the case. Take the new front assembly and turn it over (as shown below) and install the caged needle bearing for the low gear on the shaft. Insert the new assembly into the Atlas case.
PAGE 10
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 10 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Use Loctite 518 to reseal the shifter control to the Atlas case. Insert the shift rails into the back side of the case and guide them through the shift forks inside the Atlas. Once installed, bolt the shifter control into position with the three bolts and torque to 25 ft./lbs.
PAGE 11
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 11 of 12 Rev. Date: 06-18-08 P/N AB1000 & AB1001 ATLAS 2 SPEED REBUILD KITS Helpful hints for installing the Atlas cluster gear: Grease the back sides of the thrust washers and set the washers into the case, ensuring that the tabs of the thrust washers fit the slots of the Atlas case. The grease help hold the thrust washers in place while the cluster is installed.
PAGE 12
ADVANCE ADAPTERS, INC. 4320 Aerotech Center Way, Paso Robles, CA 93446 ASSEMBLY INSTRUCTION SHEET Page 12 of 12 Rev.