Warn Overdrive removal

I've got a Warn Overdrive.  My research leads me to think it's an early 60's model, based on the shifter handle and the 1 1/4" intermediate input shaft (which is common for the later years Dana 18 transfer cases).

At minimum, I've got to pull it to get the Dana 18 off the T90 transmission since a bolt inside the Warn attaches to the end of the T90 input shaft.  A peak inside the T90 made it clear that I need to tear it down to clean the central input gear and replace the washer on the right.

So back to the Warn.  It's a nifty little add on.  Instead of a PTO access point to run some farm equipment out the back of the CJ, this box drops the output revs by 25%.

Draining the Dana 18 was disgusting.  First, a water-like substance poured out, followed by greenish yellow oil sludge that grew thicker and thicker.  It looks like a barista was having fun with vomit.  Awful.

I pulled the bolts and the linkage.

I got it out about an eighth of an inch and then NOTHING.

Forty minutes later, here's what I had accomplished.  I wanted to beat the snot out of this thing, but I kept telling myself two things: a mediocre used overdrive unit is $500, and this thing is made of aluminum, which is awfully soft and easily damaged.

Two screwdrivers and more patience than I usually have, and it came off.  The good news is that the oil delivery tube was intact.

This is the other half of the overdrive unit.  A star-shaped snap ring, a washer, and a bolt hold it on.  Take a 1/2" drive socket to loosen it up.  Apparently, it's supposed to be torqued to 130 ft-lbs, but this one was unsettlingly easy to remove.  No effort required.  Note the little bit of rust down low on the planetary housing.

Out and done.  You can see the star washer and snap ring in the pic below.  My iPad has been quite useful as a portable manual for these procedures.  In the end, this was a successful hour and a half.