sorry that this post is way late, but i'm a digester and i wasn't around
on the weekend.
rick, the od is in two pieces, and you should only need to remove the
five bolts that go into the transfer case, not the rear plate of the
od. it may sound silly, but the one thing you might check to aid in
removal is that both the tranny and transfer case are in neutral. the
sun gear for the planetary setup is attached to the main part of the
overdrive and the rest of the planetary system is bolted to the tranny
output shaft. this sun gear is helical and the synchros are straight
gears, so there is some rotation of the sun gear required to separate
the main body and planetary setup. if the transfer case is locked to
the wheels and the transmission is locked to the engine, no rotation is
allowed and you won't remove your main body.
once the main body is removed there is a snap ring deep inside the
planetary setup that must be removed and then the main bolt which
connects to the tranny output shaft. this bolt is removed by a 1/2"
ratchet extension.
mark may
57 cj5
57 fc170
58 fc150 w/saturn od
62 cj6 w/saturn od
65 cj5
73 cj5
