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I need to take the overdrive unit off my M41, out of the car, so I can fit the 4th gear cutoff switch which was forgotten when it was rebuilt, also a gasket which also appears to have been forgotten. I don't want to disassemble the O/D or the gearbox.
I'm probably being a bit paranoid here but when I pull teh overdrive off are there any bits which will fall out etc, are there any problems with doing this?
Thanks
Hans
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I have removed the trans cover while leaving the trans in the car. You can reach the 6 bolts either from below, and or through the shifter hole in the tunnel. I'd first put the trans in neutral, remove the mat, shifter boot and shifter. Then with a box end 1/2" wrench loosen the rear 4 bolts through the shifter hole. The front 2, IIRC can be reached from below the car and with the same wrench, though at this point you might have to lower the trans as suggested in previous post. With it lowered you can then slide the cover back and out. Make sure you have the right drill and tap matching the lockout switch threads. And maybe a new cover gasket standing by.
Wiring then goes through this switch en route to the solenoid, and hopefully you can orient the spade connectors so that you can manipulate your hand btw trans and tunnel to hookup the lockout switch once you have replaced the cover. (spade connectors facing the driver's side of the tunnel)
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As has been mentioned in other responses, the lockout switch is located on the transmission top cover and would most easily be dealt with on a bench. Remove the 4 allen head bolts holding the tranny to the bellhousing--I use a 3/4" long section cut from a 3/8" allen wrench. This allows you to use either a 3/8 swivel socket and extensions or a long handled 12 point box end wrench. Pull the transmission/o'drive down as a unit. Question--If you are pulling the transmission out--what's the condition of the clutch? how old is the pilot bearing in the crankshaft? If electrical switches and gaskets were left off the job, what about the rest of it? And yes, you can pull the o'drive off the intermediate housing.
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The trickiest part is getting the appropriate tools into the pace between the tunnel wall and the transmission to get at the bolts that hold the tranny to the bell housing. It takes an articulated extension and some sort of hex adapter to fit into the bolts. Since you mention wanting to install the 4th gear switch, I'm assuming you plan to take the gearbox and the OD unit down together. (Which is what I would do even if I wanted to only work on the OD unit.) Make sure the transmission is in gear. It will make lining up the splines easier when you put it back. The OD unit can be a bit resistant to being removed from the gearbox. It helps if you make sure the OD is not engaged when you shut down the engine prior to removing the transmission. Some people also suggest that you momentarily move the car in reverse, shut down the engine, and then put the transmission back in gear - not the OD. You can find more info and some useful links at http://www.vclassics.com/
Bob S.
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'62 PV544 (B20, M41), '71 142E, '93 240 Classic Wagon.
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You do not need to separate the overdrive and the transmission to do the 4th gear switch. That's just in the transmission cover.. easy stuff.
The gasket though... which gasket, and how badly does it leak? If it's not too bad, I'd shy away from removing the O/D.. maybe you can separate it from where it's leaking just a eighth inch or so as get some gasket sealant in there or something....
To get just the overdrive off, you might be in for taking a *lot* more apart than you want...
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-Matt I ♥ my ♂
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Matt,
I'm inclined to agree with you. If it's just a matter of getting at the 4th gear switch, I'd disconnect the drive shaft, loosen up the tranny mount, put a small block between the engine and the fire wall to keep the heater hose connectors from being crushed as the engine leans back while the transmission is being lowered on a jack. But that depends a lot on what kind of top he has on the gear box. If he has to drill the top to get the switch in, it would be easier to do with the whole contraption on the bench. It may be possible to get the top off with just the tranny hanging down, but I've never tried that trick, so I can't say for sure - might be worth a try.
Bob S.
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'62 PV544 (B20, M41), '71 142E, '93 240 Classic Wagon.
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"It may be possible to get the top off with just the tranny hanging down, but I've never tried that trick, so I can't say for sure - might be worth a try."
I can't say for sure if it can be done on a 120, but I have most definitely changed out a top cover with the gearbox still attached to the engine on a 140 with an early (non-remote) shifter. Disconnect the driveshaft, put a jack under the front of the tranny, then remove the crossmember bolts and let the engine tilt down as much as possible. Like you say... pay attention to the hoses and other clearance items in the engine bay as you let the engine pivot on the front mounts.
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Gary L - 1971 142E ITB racer, 73 1800ES, 02 S60 T5
BlueBrick Racing
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I would first check to see if the lockout switch is there, but not hooked up (See attached picture for the location-It's a D-type OD, but I think they are all in the same place). There might be a plug (which I never seen before) there too.
If not, you will need to remove the transmission cover. I would pull the transmission to do it. You need to check to make sure that everything is correct like the gasket is on right-> best when you have it on the bench. Also, make sure you use a fiber gasket, and not cork one!
I added a switch to a M40 transmission cover because I used a '75 M41 with the remote shifter, I think I either have a bad switch (it was a used one) or I didn't screw it down enough. Sometimes when I'm travelling down the highway in OD and hit a bump, the transmission comes out of OD (I'm using a '81 240 OD relay, so it shifts to 4th gear). So, I'm going to have to replace the lockout switch with a new one I have.
Paul
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A came across this cross-section of a D-type OD. The lockout switch is in the lower left corner. I just thought it was interesting.
Paul
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Thanks for everyones help, overdrive came off easily, it wasn't the lockout switch but the activator on the selector rod that was missing. fortunately I had these bits in a box.
Cheers
Hans
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