Overdrive Issues

I installed a New Overdrive years ago. After having problems with it popping out of direct drive. I gave up and removed it. (Can't go 4 wheeling in overdrive.)

So I get it thinking about it. I should see it I can do something about it. I noticed that I could get 1/8 more travel out of the shift fork with out it hitting the case. All I need to do is re drill the fork and preposition it to get more engagement.

Now the Shifter Slider Ring is right in the middle between the synchro Rings.

I only need a Seal kit to reinstall it. Hope this works.

That ware on the inside of the case. That was from cooking the bearing from shimming to much behind the Planetary Gear. Had to rebuild it.

 

I'm curious as to why it kept popping out of gear... That's not a normal thing and you shouldn't have to modify it like that.

 

Good luck! My buddy had similar problems with his overdrive, he also pulled it out and gave up, hopefully this solves it for you.
Edit because I forgot:
If you haven't already give Herm or any of the other guys at ATV manufacturing a call. They're the most knowledgeable guys I've ever spoken with regarding CJ5 drivetrains.

 

Your gonna have to wash your hands before you get sick. The virus is gonna get it.

 

Never doing business with him again. The last new overdrive I bought from him wasn't new. (Tried to send it back to him and it got lost in the mail.)
This one's better. It's from Advanced Adapters.

 

Overdrive Storage Box.

 

There are more knowledgeable folks out there.

 

But...

 

Shift fork and shaft were not good and it didn't come in a factory box. That's how I knew it wasn't a new unit.

 

That's interesting, I hope this one works out better for you! I'm eager to see if the adjustment fixes it, I think my buddy might still have his OD laying around in some box in his shed...

 

what do you mean it didnt come in a factory box?

 

If it was new. Someone had to manufacture it. Herm isn't making them out of his shed that he work out of.

 

I was looking into getting an overdrive from AA before you told me about all the problems you had with yours on last years rubicon trip. When you metioned the fork not getting enough travel to properly engage i thought it might be the shift linkage ratios not being right. I hope its as easy as relocating the fork on the shaft.

 

Loaded the Planetary Gear today. Looks like I should have full travel for direct drive.

 

Here it's in Overdrive.

 

I am very familiar with Herms operation..just didnt understand what a box has to do with the quality of an overdrive?? Herm has always treated me well and I wouldnt hesitate to buy from him. I'm not saying him or his products are perfect but in my opinion he always makes it right if it truly is a quality issue.

 

So, I see that you moved the roll pin on the shifter fork. Did you replace the 2 piece roll pin with one that goes straight through?

If so, please take a closer look. You may find that the front support for the shift fork tube hits the roll pin(s) on the inside of the tube. Thats why they were 2 short pins. It won't go into direct drive if this happens.

 

Good call, I had this exact problem when I rebuilt my overdrive. Totally forgot about it till I read this post!

 

Advanced Adapters didn't drill the hole all the way through the fork. Only the Shaft is drilled all the way. The roll pin is really short. If you pound the roll pin flush with the fork you will not get it out. Vise Grips made easy work of this. I did notice the guide pin and didn't make the mistake of blocking the hole.