Warn overdrive removal T90

Searched around here, Google, to no avail. Trying to figure out what else needs to be removed and HOW to do so on this Warn overdrive unit? Help?


Case and linkage came apart easy but not sure what to do next. Info I'm finding isn't showing the shaft in the middle, write ups I've found show things looking different than what I'm working on here.

 

I recently made this same mistake...
Put the case & the big nut back on, and that shaft comes out as a unit with the rear case.
Oh, and dont lose the little springs and synchro dogs!

 

Should come out like this-

 

no kidding!? So I remove the main bolts and then gently prying against the outer OD housing will pull the rest of the guts out of the transfer case?

 

Exactly. Try 2 small prybars (or large screwdrivers) and pry against both sides at the same time, so you're pulling straight back.

Lots of good info here-
http://www.advanceadapters.com/prod...n--warn-overdrive-for-dana-18-transfer-cases/

 

Herm has removal instructions on his website
http://hermtheoverdriveguy.com/?page_id=1136

 

It worked! Thanks for the info and links guys!
So the rest of the planetary gears and such remain in the transfer case, correct? What do I need to plug that all back up and make it functional without the OD?

 

The planetary & bowl gear assembly is held in the transfer case by a special snap ring & nut. They're kind of a pain to get at, down inside the planetary gear assembly. If you want to remove the overdrive and run without it (I don't know why you'd want to) you'll need the stock type drive gear with the correct tooth count, the nut & washer that hold it on, and the cover plate for the back of the t-case.

 

DO NOT UNDER ANY CIRCUMSTANCES GET AN AIR IMPACT ANYWHERE NEAR AN OVERDRIVE!!!!!!!!!!!!!!!!!!!!
Many have been turned to junk by doing so. They will come out with a regular ratchet or breaker bar.

 

Very easy do destroy the bearings in the inner gears from the impact. The nut is also prone to breakage and it is almost impossible to remove if you break the nut off. These units are actually quite fragile and can be damaged very easily. Very simple directions on Herm's site, as well as the original Warn instructions which both warn against the use of impacts.

 

I just can't leave it Howard. Do any research on the topic and every expert alive today will say the same thing that I have posted. This is a searchable document and using an impact to remove a nut that is very prone to failure is simply bad advice at best and quite likely to destroy a valuable part at worst. On this one I have to just plain say that using an impact to remove the nut on a Warn/Saturn overdrive is an absolute NO.

 

I've used an electric impact to remove my OD half a dozen times and had no problem. I'd hardly call the nut fragile. I do not, however, use an impact to tighten it back up.