Warn/Saturn Overdrive install 79cj5

yes I will pot some more pics soon!

 

I watched the video, pretty cool... Kinda like a semi. I love the co-pilot.... My little girl is seven now... She does the same thing...

 

Ok I sat down and figured it out. Here are the ratios of all 16 forward an 4 reverse gears my jeep has and final crawl ratio in forward and reverse.......I think i am officially a jeep nerd.
Forward Gears:
1st)_____________6.32 Low1st)___________15.54 Final Crawl Ratio forward_____________55.01
2nd)____________4.74 Low2nd)__________11.66
3rd)_____________3.09 Low3rd)___________7.60
4th)_____________2.31 Low4th)___________5.68
5th______________1.69 Low5th)___________4.15
6th)_____________1.26 Low6th)___________3.09
7th______________1.00 Low7th)___________2.46
8th)______________.75 Low8th)___________1.84
Reverse Gears
R1______________7.44 LowR1_______18.30 Final Crawl in reverse_____________64.78:1
R2______________5.58 LowR2_______13.72

 

Hey 47v6, Here are some photos of the unboxing. I will post some of the install once it warms up a bit. The school I work at had a delay today because it is -13 out and windy.

 

I wanted to do a little unboxing review of the saturn overdrive... Here it is. First impression... I ordered it in-line from advanced adaptor. It took about a month for me to get it once I ordered it. They were very nice on the phone when I called to check on the status....although I feel they jerked me around a little, because They said it was going to ship on Friday then I got an email on Monday saying it was backordered. Anyhow, I finally got it. it was packaged very well and came in a very sturdy large box



The Planetary and the main housing was triple wrapped in paper and taped.


The syncro ring was packed with grease and did stay put during assembly.

 

Wow, that looks like a nice piece of engineering.

I have never seen an overdrive in person. It replaces the bull gear?

 

So The first thing I notice and was slightly disappointed by was all the casting flaws. You would think that considering how expensive these things are that it would be premo quality. It doesn't seem to effect anything but i just don't like seeing all the holes it. If it leaks i'm going to be angry.



Very rough casting marks


Holes


More holes!



It is installed and works great but that just bugged me..

So here are some of the goodies I got with the actual OD




More Crappy casting


More goodies








The book it comes with is pretty thorough. It the same pdf you can download on line.

 

Yes. It's a direct bolt in into the back of the transfer case. The only other mod required is to cut a hole in the floor for the shifter.

 

bolts right in. Thats what i thought but these pics show me in great detail.

To me, thats a bad casting. These are NEW right? not a rebuilt husky or warn or whatever?

 

I don't have any pictures during the install, I did it by myself and it was cold so I didnt feel like taking pictures plus if I got grease on my wife's fancy SLR camera she would not be happy. But in a nut shell. I removed the PTO cover. Removed the output gear and slid the Planetary on the shaft.... sounds easy right?......Wrong! I had a terrible time getting the Planetary to slide onto the shaft the whole way. I made sure there were no burrs or debris but it just felt too tight. I really didnt want to but I carefully used a rubber mallet to tap in on far enough for the threads of the special lock nut to catch. Once they did, the threads were able to easily seat the planetary gear all the way on. Then came the most difficult part....Torqueing the special nut to the correct torque value and getting it to stop in the correct position so that the special lock washer could go all the way into the little secret groove. I had to loosen and re-torque 2 or 3 times to get this to happen.. It has to be EXACTLY Lined up with the little notches in the housing for the washer and snap ring to go in all the way... I know I sound like I'm a whiner but I'm just recanting my experience. Then I got my depth mic out to measure the protrusion of the planetary... It is supposed be .677 from the transfer case.... Mine was around .698. I didnt know if I should try to shim it or just go with it. I figured I would give it a try. So I slid the main housing on and a new gasket with a little bit of silicone on the bolts. I torqued the 5 housing bolts and filled her up with lube and it was done.... Then I moved on to the shifter linkage... I will post some pictures of the installed unit later...

 

Yes brand spanking new, with "new" holes in the casting... HAhaha has anyone else had this issue?

 

Personally, for 1009.00 plus shipping I would send it back. Castings should not have voids in it from my experience. Maybe I'm wrong. Wouldn't be the first time.

 

Well That's another thing I wanted to mention... It says 1099 +shipping but when I added it to my cart and checked out it was 799. Maybe that's why i got the one with holes in it... haha