Warn Stuck in Over Drive

My warn overdrive is stuck in overdrive it will shift from overdrive to neutrual but will not go into driect. Any thoughts? Before I took it to the trans shop to be resealed it worked fine!!!#%%^&!!!!! I am thinking the guy that took it apart was not very good and put something in backwards or something. And to top it off it still leaks

 

sounds like the synchro dogs have popped out and won't let the collar come back far enough
is this the first time you've shifted it since the repair ?

 

Yes its the first time I have tryed and and tried but just will not go in Driect. I hear no bad noise coming from it at all thats a good thing. It goes in and out of overdrive at speed no problem but not into direct.

 

maybe he put the shift collar in backwards
me thinks it needs to come back out
not what you wanted to hear....

 

Well I called the shop other day and told them what was going on there going to make it good but last time the tranny and transfer case was in the back of my pickup truck now there going to have to pull it at there cost they said not a problem so what your thoughts about driving it 10 miles or so to get it down to the shop?

 

if it were me, I'd pull the odrive off myself..
if you're not able to do that, then you need to get it to them
the danger would be if one fell out and went thru the odrive....
I can't recall if that's even possible or not, one to fall out of place
are you able to remove the odrive yourself ?
we can walk you thru the procedure

 

Ya I Can Remove it. I remember something about a star washer to take off the drive gear

 

there is a special snap ring in front of the star washer
once they are removed, then a 1/2" extension can be inserted to loosen the nut
maybe you should take it back to them first
if you remove it, they might say it's your fault....

 

I think your right! I think Ill load it on the trailer and drop it off this week. I can take it apart but I think they need to fix it sence I paid for it to be done right the first time.

 

Ok I pulled the overdrive out today when it was up on the rack and what I found was the shifting tube that carrys the fork rides on a guide pin in the back of the case. Well the roll pin that holds the the shifting fork on hits the top of the guide pin in the back of the case and will not let the unit shift back into direct drive anyone seen this one I dont know the fix for it ??????????? I can't see any thing wrong Help Please. thanks guys

 

too long a roll pin ?
it should be flush on both sides
here's a couple pics of the extra one I have
I don't see how the pin could hit anything
does this help ?

 

JPFlat2a Does the pin go all the way across the shifter tube mine it hits on the inside of the tube on top of the shifter guide pin?????

 

yes
on mine, the fork and shaft are drilled all the way thru

 

correction: the shaft is hollow to fit over the guide (duh)
two very short roll pins secure the fork to the shaft
should have looked closer before I opened my mouth (duh)

 

The roll pin is flush with the side but the problem is on the inside of the tube when you close the case it push shifter fork back to neutral or you can pull back to overdrive it will not let it go to the direct gears.

 

flatfender motto
"be prepared" for anything

 

the shift fork is offset
is it on correctly ?
(assuming the one in my pic is on correctly?)

 

Thats the problem when they put it back together they used a new pin that goes all the way across cool thanks jim that helps a bunch

 

okay
make sure the new pins don't extend into the hollow cavity to hit the guide pin