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I wanted to find out whether there was anything wrong with mine, and whether I could do anything to get sustained flow again. For disassembly, all that is required is a 4mm allen wrench or driver for the head bolts, and a 14mm wrench for the output fitting.

After studying the head for a few minutes, it became obvious that there was room to port the intake and output ports. Each port is covered by a flexible steel flap, and when the piston is on the downstroke the flap opens to allow air in to the chamber. Then when the piston is on the upstroke, the compressed air forces open the output flap. These flaps make excellent templates for the porting.

Using a router bit on a Dremel, I removed the rib and a bit of extra material on the intake port for a roughly 25% gain in flow capacity. I used the Dremel to effectively double the size of the output port.

 After a good cleaning, I reassembled the compressor, and using parts from leftover projects installed a brass, barbed output; and a new coiled hose (the original hose fittings leaked at the assembly that is screwed onto the valve stem). Then I sourced a zooty Type R filter to replace the original plastic and sponge filter for more airflow and a touch of bling.

The MV50 is rated at 150 psi and 2.5 CFM and when new, it could inflate a 33" tire from 18psi to 35psi in roughly 3 minutes. After this cleaning and porting, the MV50 sustained airflow over multiple fills and consistently aired my 33's from 18psi to 35psi in just over two minutes per tire. This is a very satisfactory result for 1 hour of time and $7.

Instead of shipping the transfer case back to Advance Adapters, I decided to replace the input shaft myself. Replacing the input shaft myself saved time from not having to wait on shipping both ways and gave me the opportunity to write a "how-to" which will hopefully help someone out in the future.

Advance Adapters sent the 31 spline input ring assembly with the bearing and seal installed already. This eliminated the need to press out the input bearing and replacing it along with the input seal. Before the 31 spline input goes in, we obviously need to take out the 23 spline input.

The first thing I need to do was get the Atlas on a work bench and flip it upside down without damaging the breather. You can either remove it or put the Atlas on a block so it doesn't sit on the breather. You will see the the inspection cover being held on by 14 bolts. Remove these and remove the inspection cover by utilizing the pry points on each end.

Once the inspection cover is removed, you will need to remove both the front and rear cluster pin bolts then push the cluster pin out from the front while holding the cluster gear with one hand. Lift the cluster gear from the case being careful to not let the needle bearings fall out from inside the cluster gear. Once the cluster gear is set aside, remove the two thrust washers.

Once the thrust washers are set aside, remove the 6 bolts holding the input ring to the Atlas housing and remove the input ring assembly. Remove the drive gear from the input assembly by first removing the snap ring then the drive gear. Advance Adapters says this is a light press fit, but sometimes it can be pulled off by hand. Install the drive gear onto the 31 spline input assembly and make sure the snap ring is seated in correctly.

The most important part of a winch installation is choosing the right location for mounting. The front bumper area is the most logical choice, but beyond that, where in the front bumper area should it be located for the best access for use and the most protection from street and trail damage is the question.

As you can see pictured at right, I chose to mount the winch as low between the frame rails as possible without protruding below. I chose this location for several reasons. First, the finished winch install will not inhibit airflow to the radiator. Second, this location allows for a much cleaner looking installation and retains the use of the factory front bumper. Third, mounting in this manner makes it much more difficult for someone to steal.

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