I am sure you have found this in your reading but it bears repeating.

Stall the car by releasing the clutch (brake on) while in reverse. This will enable you to slide the overdrive unit off of the shaft once all the fastners are off.

I found that cutting a 10mm wrench down in length made it much easier to remove the nuts on the top of the OD unit. There is a picture of it and the tool I made to remove the caps on the unit in the FAQ's.

Good luck,
Randy

...for general OD removal steps.

Driveshaft removal is covered in section 450. The flange on the OD output shaft has to come off too, so the OD can come off.

For the top 2 nuts, with the tran as low as possible, I used a 1/4" ratchet and a short 7/16" socket (AFTER the socket was shortened by another 1/8" inch or so—to a nominal .700" overall). Some masking or friction tape on the socket made it grippable for easy finger-turning without the ratchet, once the nuts are loose.

Putting the "new" OD back on can be tricky as two rotating parts have to be lined up so their 22-spline teeth will slip onto the 22-spline output shaft. I aligned those parts with a home-made tool — a cheap plastic 22-spline clutch alignment tool (see IPD pic below) that I modified and epoxied to a 6" dowel handle that I inserted into the back of the OD (think anal probe ;- ) It took 2 tries to get the OD seated, on my back under the car.



This was several years ago, so I don't remember much more.

--
Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Hello,
What parts do you have that you are going to install.
I have done the OD repair a few times and I have never
had to remove the drive shaft. The OD solenoid sits
on the upper side of the tranny near to under the
driver's seat, it is held on with two 13mm bolts.
(picture at http://www.vcoa.org/700-900-faq/ImagesProcedures/ODSolenoidBoltAccess.gif)
I bought a wrench with a neck that bends so to have
access to the bolts.
(see picture at http://www.google.com/products/catalog?hl=en&q=13mm+wrench&ved=0CB0QzAMwAA&cid=7549955788526471058&sa=image#p)
Try to clean the area off first
so as to avoid any gunk falling into the hole once you
remove the solenoid. The wiring runs up onto the passenger
side of the car then up to the gear shifter. Have you
checked the OD relay, that may be the problem. Did you
order the two ring rubber washers that fit in the
solenoid? Have you listened to the solenoid when you
press the OD button, it clicks if working fine but
can still have an issue if one if the ring rubber washers
is worn out. If I remember correctly the solenoid has
to be touching the tranny to make the electrical contact,
if it is just hanging loose it will not click on or off.
If it does not click it might be the OD relay or the wiring
and not the solenoid itself. The relay sits to the left
of the glove box, you have to remove the glove box and
then you will see it on the left side behind the console.
(see picture at http://www.ipdusa.com/uploads/images_blog/484.jpg).

Good luck and let us know how it worked.
Joseph in NM/AZ