Overdrive Problem

It's a brand new Advanced Adapters Overdrive. I drove the Jeep to work today to try out how it drove. Worked great, until I drove it home. Now it pops out of direct drive. Doesn't make any sense. The instructions give a measurement how far the gear is suppose to extend out the housing. Mine is out .080" farther , but doesn't bind. Now I'm thinking it could be the Novak Main Shaft. Could it be that the Main Shaft is walking forward? Could a SM465 shaft move forward? I had the transmission professionally rebuild about a year ago. Anyone know anything about the SM465? This sucks. This is the second overdrive that did this.
I called AA. They blame Novak.

 

scott,
i've heard that the front bearing is something to look out for?? i guess you can't go by year of the trans but by the thickness of the bearing to get the wrong one? i may run into this when i install my 465 here soon. would that wrong bearing push the shaft back creating the overdrive to not engage properly? there is a guy on ebay that has that info on his ad when buying a rebuild kit. something to look into i guess. maybe someone with some knowledge will chime in soon.

 

Is this your installation instruction you referred to? --Before assembly, you must verify the proper location of the gear assembly. This measurement of .677" is taken from the case to the top of the planetary.

 

Scott, I seem remember some discussion here about excessive endplay in the transmission mainshaft possibly causing issues with an OD. Not sure where, here, I read it and it may have even been during your previous OD situation. Maybe I can find it......

 

My measurement was .757"out to far and would help with the engagement. The new overdrive does work better then the old on. The old one, I couldn't even let the clutch out with out it popping out. This one does it under heavy loads.

 

Are you using the "thick" adapter with the spud shaft or the thin adapter with a one piece mainshaft to the transfer case?

 

I'd inspect everything for play. Mine had the same symptoms recently. I finally fixed it last night by replacing the main bearings in the barrel gear... That's not likely your issue, but if things move around (mine was) they pop out of direct. I tried all kinds of different shims before I investigated further and found the bearing issue.

 

1" Adapter.
I do have a thought. I'm wondering if the snap ring on the output bearing is missing. I talked to Novak and they said. The main shaft can't move that much.

 

Don't buy AA's opinion that it's the Novak parts. AA is really great about passing the buck. I know this from personal experience with them.

 

But if he's had two units exhibit the same symptoms, that would lead me to look in a different direction.

 

I took the overdrive off. The synchro ring seized onto the planet hub. When I took the overdrive gear off. I found I left shims on the shaft from Herm to try to fix his faulty overdrive. There wasn't enough clearance. That's probably why it worked most of the day until it got too hot and not engage all the way. Well. Rebuild and try again.

 

Overdrive works now. It seems you need the .677 measurement for the overdrive to work. To get this I machined .030 off the Spacer Washer. That's the washer at the base of the gear, between the gear and the output shaft.

 

I was of no help with your problem as every one of them I put on worked fine. Happy you got it working properly.

 

Good to hear you have a working OD. Glad I have OD; especially for street driving, and reverse with the granny-low T-98 transmission!

 

Good Job Scott...........

 

Just went through the same issue. Herm wouldnt admit it, but the machining tolerance of the square washer is garbage. His son finally sent us a used Warn washer, and no more popping out of direct drive...

 

Overdrive has been working fine. I did notice that Herms shifter rod (Bent plate) for the SM465 isn't strong enough. I had to weld a second plate to it. Now it is a 1/4" thick instead of 1/8".