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September 2007 Timeless Tech - Over Driven

Saturn Warn Overdrive Two Driver Gear Tooth

Saturn Warn Overdrive Bearings
If these bearings are munched, it's time to add a set to your order list for replacements. Ours were fine, so we made a needle bearing/washer sandwich. Use grease to hold eight needles in one end of the little drive gear. Then pop in the thrust washer and eight more needles. Now put the other two washers on either end and then drive the gear and pin back in to the planetary assembly.
Saturn Warn Overdrive Replacing Overdrive Gear
We needed to replace the 26-tooth overdrive gear with one that had 29 teeth, so we swapped the bearings over to the new gear and reassembled the gear/planetary unit.
Saturn Warn Overdrive Inspecting Synchro
We then moved on to the back half of the unit to inspect the synchro and to remove the bits of the broken shift fork. To start, remove the four retaining bolts that hold the back cover plate in place, then the cotter pin, large nut and spacer, and finally, the bearing.
Saturn Warn Overdrive Removing Two Hex Bolts
Remove the two hex bolts and separate the rest of the housing. You can now remove the shift rail, detent spring and ball, and the solid driver from the housing.
Saturn Warn Overdrive Improperly Installed Synchro Rings
Our Saturn looked like one or both of the synchro rings had been installed improperly, which eventually caused the shift fork to snap like the bad guy's neck in a Bruce Lee movie. When rebuilding and installing the Saturn, you must be sure the three notches on the synchro rings line up with the three shift dogs on the synchro block assembly. If not properly installed, there will be a gap between the overdrive and the transfer case when you try to install the unit.
Saturn Warn Overdrive Shift Mechanism
You can focus on the shift mechanism. Inspect the synchro ring's shift ring and drive member for excessive wear. Pay attention to the shift dogs and springs when removing the shift ring from the drive member because they will love to jump out and hide under something if allowed to.
Saturn Warn Overdrive Gasket Kit
Order all the parts you need, plus the seal and gasket kit, wash the housing, and wait. We would do this as quickly as possible to avoid lots of time spent forgetting how you took the thing apart.
Saturn Warn Overdrive Overdrive Complete
When the new parts come, reassemble your overdrive, install it, and blast on down the road. Don't forget to replace all of the gaskets and seals.

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