Specifications

New design Old design

SPECIAL CONSIDERATIONS:

The photo below represents the snap ring, lock ring, and retaining nut that fastens the planetary gear assembly to your transfer

case. These items are only accessible once the case assembly has been removed. To remove the case assembly, unbolt the five

3/8” bolts. The case assembly should then be removed. (NOTE: On high mileage units, the unit may be difficult to separate. This

is due to the caged needle bearing that was originally pressed into the planetary hub. DO NOT disassemble the case assembly

from the bearing cap inward.)

Once the case assembly has been removed, you should have access through the middle of the planetary housing to remove the

snap ring, lock ring, and nut. See illustration below. Whenever the snap ring and lock ring are removed, they should be replaced

with new components.

Step C5

Thoroughly clean and inspect all parts. Replace any if neces-

sary. Reassemble the case assembly in the reverse order.

Step C6

Be certain that the notches in the rear synchro-rings are aligned

with the shifter dogs when assembling. To properly retain the

outer brass synchro-ring during assembly, we recommend

using a quality grease to hold this ring in position. All internal

components should be lubricated during reassembly using

SAE 90w gear oil. Remember to install the oil scoop, as it is

crucial for proper oiling of the unit.

The design of the planetary housing has under-

gone a few changes from the early Warn & Saturn

units.

One of the biggest problems when installing &

removing this unit from a vehicle is the caged

needle bearing that rides on the 6 spline shaft.

This bearing required a pressed fit when installed

into the planetary housing.

Today we have designed the planetary hub and

the 6 spline shaft to simplify the installation & re-

moval. Instead of the caged bearing being pre-

installed on the 6 spline shaft, we now install it

first in the planetary hub. This required a snap

ring groove machined in the planetary hub. The

retaining hub on the 6 spline shaft was removed.

Current production of these 6 spline shafts, with

the use of the older style planetary hub, will re-

quire this snap ring groove to be machined. Refer

to the illustration on the left.

saturn overdrive