Overdrive shift fork

Anyone out there ever replaced a broken shift fork on a Saturn overdrive? I have the housing pulled off the back of the t-case. Just not sure about the dis-assembly of the housing to get the shift rail and broken fork out.

 

John, you may have this info already, but here it is.
http://www.cj-2a.com/_Media/saturn_od-2005.pdf

or
http://www.cj-2a.com/rebuilds/warn_overdrive/reassembly/index.html

 

Or www.hermtheoverdriveguy.com

 

That link to the 2A site was exactly what I was looking for. Thanks guys. Good to know in advance about how the roll pin has to go in the fork. That's the kind of stuff that can ruin most of a day if you didn't know about it. I went to Herm's site, but the info wasn't as detailed as the 2A site.

 

Everyone likes pics of carnage, so here ya go. In my online research I discovered that AA had a problem with their re-engineered shift forks, but all the ones I saw pics of were broken where the roll-pin hole is. Never saw one broken like this. The fix was relatively easy as I didn't have to remove the barrel gear, just the shifter housing. I wanted to get a Warn fork as they are made from bronze rather than the aluminum that AA uses, but Herm said they won't work on a Saturn OD. For what it's worth, I can tell you that I never abused this OD, obviously it was a poor casting, although it did last me for about 8 years.

 

ooooooooo aaaaaaaaaaaa I love carnage

 

Ya, I'll be carrying my bull gear and all the tools I need to remove the OD on any difficult trails I run. . . just in case. I never had any issues with the Warn OD I had on my Willy's Wagon. But this Saturn has taken a dump twice now.

 

You weren't the only one........although I replaced it with a brass one, works fine

https://picasaweb.google.com/lh/photo/G6fgX9TwnLVFXJlzqsFOi9NaRFIsnmptQOSgHBDK53U?feat=directlink

 

Herm told me that the Warn fork wouldn't fit my Saturn. I didn't ask him why. Did you have to modify the fork? Mmaybe the roll pin hole is in a different place on the shaft? I would have much rather used the bronze fork.

 

They were both identical, the bronze (brass?) fork came from an old Saturn that I got w/ the jeep. No modifications, defintely a stronger setup.

 

Well, I would have said weak material and/or poor design. The casting looks ok from the picture.

Good carnage though.

 

I don't do well posting pics but here a link to my old and old new fork.

https://picasaweb.google.com/115996...hkey=Gv1sRgCIGdk9bRieO2EQ#5705415417187677746

 

I think it's both. There is not much material where the fork broke and it appears to be aluminum. I'm not sure about the mindset that says re-engineer something that works into something that's cheaper and doesn't work.

 

After a discussion with sgojpn (Mike) about the bronze shifter fork (original to Warn OD's) I decided to order one from Herm. I haven't put it in yet, but Mike has and he says it fits just fine. It's much more beefy looking than the AA version. When I get a chance to put it in I'll post some more pics. Also, I replaced the missing pics at the beginning of this thread. It's been annoying losing all my Webshots photos, but I'm slowly getting them all back in the threads they belong in.