Dutchman

Sweet! Thanks Don! I can’t wait to get it.

Great Idea Jim! I’ll make sure to document what changes George made to the OD.

Sorry Doug, i didn’t get a chance to send the list last night. Got home way to late last night. Here is a list of parts that George explained to me what he will need to rebuild OD: Ring Gear Planetary gears Sun Gear The piece that the sun gear goes into. it has 6 slots where the paw for the solenoid plunges into. he calls it the “dog" Sprag, which according to George is the clutch at the end that has the cage with all the rollers. George said that everything pretty much inside the OD case excluding the main shaft was damaged and would need replaced. If you have any questions, give me a shout. Also, I have Georges Address. Send me a pm and I’ll send it to you and let me know how you would like me to compensate you for shipping and such and I’ll send you funds right away. Thanks Doug!

Hey Doug- I just heard back from George and he said that my case was repairable. He gave me a list of parts from that Chevy you have that he could use to rebuild it. When I get home tonight I'll send you the list of what he needs. This is good news! They found some cracks in the case, but successfully braised them and then bored out the inside to accept the Chevy ring gear! I'm really excited that this is going to work out!

Sorry for the delay Doug. I’ve been busy traveling to Viva Las Vegas and back. I talked to George yesterday and he said he believes the case is salvageable, but he will have a definite answer by the end of the week. George said once he knows for sure that the case will work, he would like to use those chevy parts if you still have them Doug. He is looking for the Planetary Gears, Sun Gear,rollers and what he calls the dog, which I’m a little unsure what that is. He explained that its the part that is normally attached to the adapter plate. If you have any questions let me know. I will let you know as soon as I hear back from George if everything is a go. Then let me know what the postage is and what method you would like me to send funds to you and I’ll get it to you. I’m trying to hunt down Georges address for you, I misplaced it at the moment, but should find it here soon. Thanks again, Dutchman

Well, I sent my rear case to George for him to check it out and possibly rebuild it with Chevy parts. He said that the chevy R10 Sun gear, Planetary gears, ring gear and sprag with the rollers would work from the 62 Chevy OD. Doug- let me know how much you will need for the parts and when I her back from George, I will send you $ and you could send the parts straight to George. Hopefully this will work great in the end! Thanks! Dutchman

Yes, I should be able to. Thanks!

Just curious...if the GM ring gear is not supported by the rear case, how is it supported?

Thanks, Doug! I’ll try to contact George and see what he needs.

Hey martybose- I know the oil you need and you can get it at Napa. It is called Napa Mineral Gear Oil SAE 90 API GL-1 in 90wt. I’ve ordered it from Napa 2 times and it comes in a gallon container. Also 65-201 may be the order number. Hope this helps! Dutchman

Thanks Plyroadking! I was wondering as well if I could drill and weld the crack or perhaps find a way to sleeve it. Any thought on sleeving? I did talk to George and he said that he has been trying to fin a rear case for one of his costumers for 2 years! Yikes! he also said he successfully machined a case to accept a larger Chevy planetary setup. I just don’t know if the crack is going to spoil that idea. The oil was dark and nasty looking when I tore it apart, even after I had drained the original oil and replaced it with new 90wt mineral oil, then ran it for quick and short drive and then replaced it again with mineral 90wt. to clean it out. something must have been getting hot.

Thanks Guys! Doug, let me know if that chevy OD is available and how much. Also what model it is and perhaps George and I can find out if we could make it work. Thanks again for everyone help and input!

Thanks Jim!

Here are some pics of the inside of the OD case and there does look to be some scoring and perhaps a crack at the bottom?

Thanks, Dodgeb4ya- I didn’t see your post since I was working on sending my last one out. I will have to check my case for wear. if there is wear on the case does that mean I need to find a new case and if so are they even available? I was thinking that perhaps the chewed up roller was the initial cause for the failure, but the wear in the case may have been.

Now that I have the entire insides of the OD transmission out in open view I could start to removing parts to see if I could find out the damage. Everything from the transmission side to the adapter plate seemed to look in good shape. Then while looking in the bottom of the OD housing I noticed that there were small bits of chewed up parts. I then attempted to pull the OD output shaft from the pinion cage and roller clutch assembly. It would not come off easily and after many strikes from a rubber mallet, I finally drove the main output shaft away. When the shaft came off there were several rollers that fell out with it and one roller in particular looked like it had came off a some point and mixed it up with the planetary gears and sun gear. All 3 Planetary gears were broken off their posts The damage was clear! So the planetary gears and the sun gear are toast as well and the roller clutch cage which looked really pitted or oxidized. After I pulled the two retaining clips from the pinion cage assembly and the overrunning clutch, it took a puller to remove the Pinion cage and a little finessing to finally get the planetary gears and sun gear removed. So this is where I’m currently. I guess I will be looking for a new planetary setup, sun gear and overrunning clutch. and possible a new rear OD output shaft and maybe more parts. Anyone know where I can get these?

On Tuesday, I had had a chance to successfully tear into the OD transmission. Many thanks to Jim for the files he sent me to make this possible. I was unable to make any posts until today. So here are some photos of the teardown and what ultimately lead up to what I found: Heres removing the first shift rail or rod after I had removed the transmission cover taken the two balls and springs out and removing the set screws on each shifting fork. Here is the smaller 2nd shift rail removed Here is the first shifting fork being removed. I was not able to get the second Large rail and shifting fork out due to the appearance of a plug. But that did not keep me from being able to remove the entire transmission shaft from the main housing. This allowed me to access and remove the two screws that attach the adapter plate to the OD case. I then was able to separate the OD case from the transmission and what I had left was pretty much the guts of the transmission shaft, adapter plate and the overdrive gears and the OD output shaft. Now this is where it gets interesting!

Hey Jim- Thanks for the extra files you sent me. I used the maintenance one and it really helped me get the OD separated from the transmission.

Sweet! Thanks for the info! And yes the fuse was in good shape. I did notice when draining the oil out of the rear OD drain that there was some pieces in the bottom of the case. It looked like reminants of a bearing cage! So I'm pretty sure the OD is locked up somehow. I'll take pics and show everyone what I find.

Also, sorry for creating a new thread guys... I thought since this was a new problem and I was not the one who started the original thread that I might have been highjacking. My mistake, I’m a new-be. I do appreciate everyones ideas and input.

You know, yesterday I ran my finger around on the inside of the adapter plate and felt two straight slotted screw indentions and thought, “I wonder if this is holding the adapter plate on and keeping from removing the OD housing?”. It just didn’t say anything in the manual, so I was afraid to start tampering with those. THANKS for the valuable info! One more question... Do you have to totally remove the main shaft out of the transmission box with the OD in order to get the OD housing off or just out far enough to remove the two bolts? When separating the case I can move the main shaft out a few inches but after that it won’t come out any more. I thought perhaps getting a 90 degree slotted screwdriver in there and removing the two bolts.

Got a quick question if someone has disassembled one of these before. It’s hard to understand in the manual where exactly you want to separate the transmission and the overdrive when pulling off the OD housing. should you separate at the point where the OD housing and the adapter plate meet or should you separate it at the point where the Transmission and the adapter plate meet. Mine at the moment only seems to separate at the transmission and adapter plate. Hope this is not confusing. I wonder if I need to separate the OD housing at the point where the adapter plate and the OD housing meet. I tried to bouce a rubber mallet against the seam to see if I could get it to break loose there, but it didn't budge. I know later in the manual it says to put a case bolt back in to secure the adapter plate to the transmission housing in order to pull the OD main shaft out and catch the clutch rollers in your hand at the same time.

This is a continuation from Overdrive noise that was posted earlier. to make a long story short. I was on my way to town yesterday and may OD which I just installed last week started to make noise and then all of a sudden it kicked me into direct drive. And I could not get it back into OD. I check all trouble shooting ideas per manual and tested all electrical components and everything seems to be working. I can drive in direct in all three gears & reverse, just no OD. So I thought something may have seized up internally. so I removed the OD/tranny this morning drained the oil out of both front and rear. there seems to be some pieces of metal in the bottom, thin like a remnants of a cage or something. Not good. SO I put the OD/tranny on the bench vice and stared to take everything off per the manual. I took off the universal joint flange/emergency break. taped the pin out on the manual lockout lever and pulled the lever out as far as it would go which was about a 1/2 inch or so and then removed the 4 case bolts. When I got to separating the OD housing from the transmission it says to tap on the OD shaft as you remove the OD housing so the shaft stays with the transmission and the housing should slip off. That was 3 hours ago and I cannot seem to get the OD housing off of the shaft. something is stuck. I don’t know if it is a bearing or if I’m missing something. Any info would be greatly appreciated.

well I got the OD/tranny out put it on the bench vice and stared to take everything off per the manual. taped the pin out on the manual lockout lever and pulled the lever out as far as it would go which was about a 1/2 inch or so and then removed the 4 case bolts. When I got to separating the OD housing from the transmission it says to tap on the OD shaft as you remove the OD housing so the shaft stays with the transmission and the housing should slip off. That was 3 hours ago and I cannot seem to get the OD housing off of the shaft. something is stuck. I don’t know if it is a bearing or if I’m missing something. Any info would be greatly appreciated. I think I will start a new thread on this as well.

I pulled the OD/tranny and drained the oil out of both front and rear and it had plenty in both. Oil looks really dark for only being in it a short time. Guess I'll tear into it and see if I can find out what's wrong.