Warn/Saturn Overdrive install 79cj5

I have a 79 cj5 with a Mercedes diesel and I have been wanting an overdrive forever so I am finally in the final stages....I just need to find an overdrive. Hahaha. I know that sounds dumb be but that will be the easy part. Since my jeep is a 79 it really wasn't meant to have an overdrive. I have posted some of my other OD preparations on this forum. so far I have, Built a large hole dana18/20 so I could have an offset output. I have cut down my standard amc 20 and put Q-trac axles in it to match the offset t-case, then I had to make a new exhaust system because of the drive shaft, Then I had to make two new drive shafts because of the different length output. Then I had to build a new tunnel cover to fit all the shifters (this is where I am currently at. I also made my overdrive shifter with grease fitting, and custom knob (delrin plastic). I am working on a templet for the tunnel cover. My wife is working on a pattern to sew me some custom shifter boots. Here is where I'm at. Thanks for looking.



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This is a lot of effort to get some more gear for highway. Cool stuff though.

 

Yeah I know. Haha it turned into way more than planned but it will be really nice. With the diesel the gears will be sooo nice. Plus being able to split gears will help with turbo lag. plus I pretty much made everything myself. The OD will be my only expense.

 

yeah, thats cool. Thats how i did everything to get mine on the road. Little to no monetary expense but lots of resourcefulness and ingenuity. Funny thing is now I am getting rid of my "ingenuity and resourcefulness"... hahahah.

 

I love to recycle materials and part. I also find it really therapeutic to build old junk. I think it will be worth the effort tin the end.

 

I got my floor pan done. It nothing fancy but it will do. I also made my trim rings. I used some spare screen door seals I had laying around to seal it to the floor. I used "U nuts" on everything so it would be easier to work on thing from inside the jeep. I used ss hardware and epoxy paint so hopefully it will hold up well. When the wife gets freed up she is going to finish up my boots. I am using material from an old bikini top. So far so good. I also need to make a little plate to cover the hole that the t case shifter pin goes through.

 

thats just cool

 

Thanks man!

 

slick design...
bookmarked this for if and when I ever get to this

 

Having a diesel engine in mine......I understand the need to split the gears and also the OD. Out of the box for sure, but well done.

 

Thank you! I have read your complete thread and really enjoyed it! Beautiful 6! I always wanted one. How do you like your perkins? How is it on fuel? Here is the build thread for my diesel conversion.
http://www.4btswaps.com/forum/showt...m617-conversion.......Let-s-see-how-this-goes-!

 

Very nice work!

 

It's definitely no turbo diesel..... it's a fuel sipper on the trail and works great! On road it's loud, slow and stinky!

 

Sounds like a "that's what she said" moment....haha

 

So, in preparation for the overdrive.....I Had a leak in my newly re-gasketed transfer case. So I figured I WOULD FIX IT. I didnt have the good copper spray a gasket for the rear bearing cap shims when I rebuilt it. So I figured that was the problem. So I pulled the rear cap and got the copper sealer.....when I was re-tightening the u joint straps I noticed the tranny moving a lot on the cross member. On further inspection I realized there was nothing holding the tranny in place. So I reluctantly pulled the belly pan and found one bolt missing and the other sheared of.... So much for a quick and easy project.. So then came out the taps and easy outs. I cant believe I was able to get it out Who knows how long it was in there for. So I got the bolt out and chased the holes with a tap and reinstalled everything with lock tight and lock washers. So no that problem should be fixed. I re-assembled everything and went for a test run.....It still leaks. not sure where it is leaking from... I actually think It may be from the shift rail caps. I will have to clean everything really well and try to find the source. Is there a trick to sealing the caps? I also finished my shifter linkage... And I found this cool red knob.

 

I wonder what could be in this box????

 

money

 

Haha! this is true............

 

I took the jeep out for a test drive yesterday..... I played around splitting gears with it. I know the overdrive wasn't intended to act as a full on gear splitter but i always wanted to see a video of someone doing that so i decided to make one. My main use for the overdrive will be to split 3rd and 4th gear, and to have an overdrive gear for the highway. Here is the video. I will do a more in-depth review and un boxing of the saturn OD soon.....(with pictures).

https://www.youtube.com/watch?v=6Q9g3bZX_Lo&feature=youtu.be

 

Cool.
I never really thought of the gear splitting attributes before. Now i look at what you're doing and it works like a 2 speed rear in a big truck. In one of those you have a gear you're in and then a button you push or pull to engage the other gear.

That is really neat. Can you post some pics of the install and the linkage.