Specifications

(Fig. 4)

(Fig. 6)

(Fig. 5)

6. Install the oil scoop into the case assembly (Fig. 4). NOTE: Be sure the oil scoop

is in place. Failure to install this scoop will cause lack of proper oiling and

eventual overdrive failure.

7. Before assembly, you must verify the proper location of the gear assembly. This

measurement of .677" is taken from the case to the top of the planetary. (See Fig. 5).

8. Align the gasket to the rear of the transfer case and install the

aluminum housing portion of the overdrive to your transfer

case. Caution should be taken to make sure the brass

synchro-ring is properly seated before mating these units

together. The three steel keys must interlock with the brass

synchro-ring. We have packed grease underneath the synchro-ring

to prevent it from falling out of position during assembly. If the synchro-

dogs do not line up properly, you will find a 1/4" gap between the transfer case

and overdrive housing. DO NOT FORCE these components together. We have

seen failure occur because of synchro-ring misalignment.

Further precaution must be taken when installing your unit so that the planetary gears mesh properly. The overdrive unit

may need to be rotated slightly to allow the gears to align correctly. Once the unit is mounted flush to your transfer case,

install bolts with lock washers and tighten to 30 ft./lbs. torque. Make certain the seal washer is installed as shown in (Fig.

6). Turn the driveline by hand to check for free rotation.

9. Install the shifter pivot mount and handle assembly to the transmission case.

Before connecting the shift lever rod to the Saturn shift rail, you must remove and

discard the small tube that was installed on the shift rail on the unit (do not remove

this tube until the overdrive unit is installed on to the transfer case). Connect the

shift lever rod to the overdrive unit and the shifter handle. Make sure you have proper

clearance between shift rod, transfer case shifter, and vehicle body to assure quiet

operation.

10. Using the new shift boot retainer plate as a pattern, mark and cut a new lever

opening in your transmission floor plate (removed earlier). Install this modified

floor plate. Install the shift boot retainer plate and shift boot.

11. Now is a good time to fill your transfer case with the proper lubrication. A high grade

of gear oil (75-90w) is recommended. We DO NOT recommend the use of additives in the gear oil. The oil level in the transfer

case must be maintained at proper levels to assure maximum overdrive durability.

12. Put the transfer case in neutral, the transmission in high gear, and the overdrive in the overdrive gear. Run the engine at

a fast idle for 7 to 10 minutes. This will circulate the oil through overdrive unit. Stop the engine and recheck the oil level in

the transfer case, and refill if necessary.

13. About 100 miles after the installation of the overdrive, check and retighten the five (5) bolts that hold the overdrive unit to the

transfer case (30 ft./lbs. torque) if necessary. Recheck the transfer case oil level once again.

OPERATION & USE:

Shifting the overdrive is done in the same manner as with a standard transmission, which is to release the throttle, depress the

clutch pedal and shift. On automatic applications, the transmission should be shifted into neutral. When the shift lever in the forward

position, the unit is engaged in overdrive. When the handle is shifted back towards the driver, the unit is in direct. The Saturn is

designed mainly to be used as an overdrive; however, it can be used in any transmission gear-shifted in direct or overdrive. Caution:

The unit should not be used in overdrive when towing or pulling a heavy load.

saturn overdrive