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Issues with Warn OD

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47cj2a View Drop Down
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    Posted: 06 Feb. 2023 at 9:39pm
I am having issues with my Warn OD unit. back story,

many years ago I got the Warn OD, t90, S18 and PTO rebuild by Herm and everything bolted together.
Before all of this the Warn shifted no problems.
well many years latter i finally got it all into a driving jeep and the only problem is that the OD unit will not shift out of over drive.
I called herm and was told to put some miles on it and it should free up. the problem is that even though i have to take the body off the jeep for paint i havnt put enough miles on the thing to free it up.

any thoughts suggestions? what could be the most likely cause of this?
should I just pull the whole thing apart while the body is off
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TERRY Quote  Post ReplyReply Direct Link To This Post Posted: 06 Feb. 2023 at 10:41pm
Linkage hung up?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 44bz Quote  Post ReplyReply Direct Link To This Post Posted: 06 Feb. 2023 at 10:45pm
I don't have any suggestions, but I put an NOS Warn overdrive in my 2a and had no issues shifting in or out.  I would think your issue means something is wrong and not just a break in thing as Herm suggested...
46 CJ2a - Buick 225, T90/D18, Warn overdrive, Rancho 2.5" lift, confer shackles, power steering, disc brakes, RandP master cylinder kit, 33x10.50 BFG KM3s
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 47cj2a Quote  Post ReplyReply Direct Link To This Post Posted: 06 Feb. 2023 at 11:37pm
As far as I can tell the linkage is not binding.
I have never heard of having to drive the thing to brake it in. Just seeing of anyone has had a similar issue and if driving it solved it 
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'98 tj a few things zip tied here and there
'93 Land Rover Defender 110 200TDI
'62 Scout 80 stock
'66 Coronet 2 dr post 426 Hemi 4spd
'68 M35 Multi fuel
'68 M416
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Oilleaker1 Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 8:27am
Never heard that it won't shift out. Usually won't shift in. I would pull the OD off the rear of the T case and look carefully at the bowl gear. If the fluted snap ring came off, the bowl gear  can unscrew and destroy all. Herm worked on my Warn , Not Saturn, bowl gear and had to remove the planetary gears to replace a broken washer. After getting it back I discovered the pins inside the planetary gears were no longer roll pinned at the front. When they shift rearwards, it blocks the snychro collar from shifting in. I called him and got a rude response. I had a machine shop mill new holes in the replacement pins and install the roll pins that keep them from shifting back. A Saturn bowl gear has spot welded pins and a large snap ring to prevent this. 

A good friend of mine had his bowl gear unscrew until he hear a loud noise. He said it sounded like $1000.00. LOL

Not shifting is your first sign it's time to get back in there. 

Also, the bowl gear acts like a centrifuge and spins metal and garbage outwards and packs the bowl gear outer recesses. None of that was cleaned out at Herms while apart. That crap can lock the needle bearing rollers and then destroy your overdrive. Good magnetic drain plugs in both the cases is recommended. Wink
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SE Kansas 46 CJ-2A Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 9:13am
Sometimes I wonder about Herm. It took six months for Herm to straighten out my brothers OD unit and he called every week. He got a different story almost every time he called. That was IF Herm would answer his calls.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 47cj2a Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 9:49am
yeah the more I think about it i am better of safe and just pull it all apart and see what the deal is. I have to reseal some areas of the combo any way might as well get it over with.

its been hit and miss with him over the years with me. sometimes i cant say nothing but good things and some times I wonder why i even bother
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'70 cj5
'98 tj a few things zip tied here and there
'93 Land Rover Defender 110 200TDI
'62 Scout 80 stock
'66 Coronet 2 dr post 426 Hemi 4spd
'68 M35 Multi fuel
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oldtime Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 9:57am
Needing to be “broken in” is nonsense .

I would  look to see if the shift rail poppet ball, spring and detent is functioning correctly.


Edited by oldtime - 07 Feb. 2023 at 10:01am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mbullism Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 12:56pm
Originally posted by oldtime oldtime wrote:

Needing to be “broken in” is nonsense .

Pretty sure "broken" is the operative word there...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oldtime Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 1:09pm
Pull the poppet ball and spring out to see if it then shifts outta high range.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Oldpappy Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 2:33pm
What Ken suggests is worth a try, and it may be something simple like that.

Always check the simple stuff first, but I would not drive it again until I was sure what was wrong. 

If, as already suggested, the snap ring wasn't seated and came out the lock nut will back off and then the hub nut will loosen until it causes major damage to the bowl gear and possibly the input gear. 

The hub loosening might put it into a bind or let it back out enough that the synchronizer hub can't disengage. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bruce W Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 2:43pm
  Oilleaker1 said,”A good friend of mine had his bowl gear unscrew until he hear a loud noise. He said it sounded like $1000.00.”

  I was there. He actually said it sounded like 
“THOUSAND!!” Ouch
BW 


Edited by Bruce W - 07 Feb. 2023 at 2:47pm
It is NOT a Jeep Willys! It is a Willys jeep.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fltfndr Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 3:21pm
This may sound like a stupid simple possible answer but I had my T/C rebuilt and when they reinstalled it along with the O/D it would not shift either. Turned out there is two adjustment holes in the linkage and if not properly assembled, O/D will not shift

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Post Options Post Options   Thanks (0) Thanks(0)   Quote 3A Steve Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 3:29pm
Had one of Herm's ODs that locked up. Figured I'd take the T90 floor cover off and look for something binding. For some reason I checked the OD shaft after taking a couple of the bolts out of the cover and it freed up. Put bolts back in and one of them locked things up again. Put a shorter bolt in and it has worked fine for years (did need a minor repair by Herm for something else but not for locking up).  Worth a try.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Oldpappy Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 3:39pm
I like "stupid simple possible answers" because I have made a lot of stupid simple mistakes my own self.

If the bowl gets loose I bet it do make a loud noise.  




Edited by Oldpappy - 07 Feb. 2023 at 3:40pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 47cj2a Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 8:53pm
thanks for the advice, all very good. 
will look into the linkage and detent ball first. removing the back will be last resort as theres a PTO attached to it so not as easy. but it might be worth it to make sure everything is at it should considering it will be much harder once the body goes back for hopefully the last time.
'47 cj2a strewn about
'70 cj5
'98 tj a few things zip tied here and there
'93 Land Rover Defender 110 200TDI
'62 Scout 80 stock
'66 Coronet 2 dr post 426 Hemi 4spd
'68 M35 Multi fuel
'68 M416
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bruce W Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 9:00pm
   Maybe I’m thinking of something else, but,,,,
Isn’t the tension on the poppet ball spring adjustable? As in retained by a bolt or screw that can be set in the proper location and locked in place by a nut? If I’m not delirious, maybe that screw is too tight. 
BW 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Oldpappy Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2023 at 10:28pm
You are not delirious, but are correct at least with the Warn unit, as pictured below, which shows the adjustment screw for the detent.




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