Atv/warn/saturn Od Shift Question

I have an ATV overdrive on my D18. I have about 500 miles on it since I got it used. I use it in direct almost always, but would shift to OD easily until recently. Now it doesn't want to shift under power but does fine sitting.

I thought it was lack of oil, but it wasn't really. When checked it was about 3/8 inch below filler plug.

So, whats the deal with this Rube Goldberg setup? Problems shifting point to early demise?

 

Check your body mounts and shift linkage. Do not force it.
Drain some oil from the transfercase and check that it flows fresh and clean.

 

Stuck my pinky in there, it’s still new looking.. every single bolt that keeps the oil in the transfer case was loose….

 

3/8" isn't low. First thing comes to mind is it's not synchronizing. I'd make sure the bowl gear is tight on the trans mainshaft / that stupid snap ring intact. Check the stickout length of the bowl gear it's very specific, a few thousand out they get fussy.

 

Are the overdrive mounting bolts loose?
The overdrive synchronizer is held tight by the mounting bolts since it shifts back and forth against the housing for overdrive to work. Does it shift from neutral to direct normally?

 

Nothing was loose enough to do anything but allow seepage. When I set this up I checked all the measurements with calipers. etc.. I will recheck everything..It worked fine until I actually drove it long enough at 60 mph plus for a length of time.

 

Shift fork has known problems.
Maybe yours ?

 

If your shift fork turns out to be the problem, I was just wondering if you could find a shift fork assy from an older warn OD unit would it interchange with the saturn or atv units?