taking off the OD

Im looking for some tips on removing the warn overdrive from the 18 t/c. I took out the 5 long bolts and used two screw drivers to pry the OD off, but I can not get it to come off.. I tried several hours with no luck, it seems the gear on the end of the shaft is stuck inside the planitary gearset. I know once I get it out that there is a special nut and snapring inside the plantary set that has to come out in order to take off the T/C, but I can't seem to get to that point.. Any ideas as to how to get the OD to pull out???? I have switched from screw drivers to small pry bars, still no luck.

 

Thanks!! I will keep at it. I just wanted to make sure I was doing it right and not break something.. Let ya know if I get it.

 

I just went through the same thing my first time last year. Use even pressure on both sides, when pulling. I ended up using 2 pry bars, about 18" long, to give me good leverage. Screwdrivers didn't have enough girth. Also, there is an oil trough that pulls out with it. It's a piece of sheet metal bent into a vee shape...maybe 1" high x 4" long.
Just wait for the snap ring and "special lock washer"...I gave up, and brought it to a shop.

 

LOL!! I will try the longer pry bars. The ones im using are about 8". It sounds like you have to use some decnt leverage to get it out, I was afraid of breaking the OD case.. I will go to longer bars and use more presure, you using a 18" bar gives me an idea as to how much presure, I will be cautous though.. thanks a lot..

 

Success!! I finally got the OD to come out, and once I got it out I seen why it took me so long. Check out the gear on the end of the OD shaft. Hope the pic turned out ok.





amazingly all of the other gears, that snap ring and star shaped clip all look ok. I couldnt find my 1/2"extension for my breaker bar, so gotta wait until tomorrow to take out the planatary gear. looking inside the t-case, from what I can see things look ok. Hopefully I can just clean it, flush it to get the metal out, buy that gear, and all will be good. Do you guys know how to get that gear off of there?? Im hoping it didn't chew up the splines on the OD shaft, and I can just pull it off and replace it.. thanks for all the help on this it was a bear.

 

not to mention your OD is toast
time to start looking for another complete OD

 

Are you serious??? Why do you say it is toast? cant I just replace that gear? everything else looks ok, not chewed up or any nicks in anything. yes I am cleaning the t-case as well, forgot to mention that.

 

The "gear" is part of the OD main shaft; there's no pulling it off and replacing it; you need the whole shaft assy ($$).
Now picture any gear that would have been turning against that gear; specifically the pinion or sun gears that compose the planetary assembly; you state they look okay; how can that be when the damage is obvious ? I wouldn't trust any gears that had been run up against the one shown in the picture.
The most expensive components of your OD unit are damaged.
When you look into the prices of those new components, you'll understand the "look for another " OD comment I made.

 

I dont know how that can be, but looking at the planitary gear set, and all of the gears in the unit they look fine except the one in the pic, even the snap ring and that star shaped retainer are not damaged. I hear what you are saying and it makes perfect scense, but im just not seeing any other damage except to that one gear. As you can see in the pic I haven't pulled the planitary set out of the t-case yet, so once I get it out tomorrow maybe there will be more damage that I couldn't see. I will just have to tear it down and see as you mention. I feared the gear was part of the shaft after you said it was toast. Man!, I don't have the money for this right now. Can I put it back together without the OD and be able to drive it with just the trans and t-case, no OD? I asked this once and believe they said I needed the a bowl gear?? and the pto cover. Can you explain that more to me, what is the bowl gear and is it removed to install the OD. If so then its long gone as the PO installed the OD. Do I have any options at this point other fixing the OD?
Thanks again..

 

When I changed my 3 speed to a 4 speed, the spline count changed on the output shaft of the tranny. Big bucks for a new gear...

 

The stock gear can replace the overdrive. You need the gear, with correct spline & tooth for your application, and the sheetmetal cover for the opening on the back of the transfer case.

 

Yup, and those aren't hard to come up with.

 

I sent herm a email yesterday with the pics and am waiting on his reply.. I guess I will track down this stock gear and live with out the OD until I can fix it. As you say, I plan to clean it all up, pull that main shaft and see what herm says. I was totally lost with this OD, so thanks to you all for your help.