fitting an overdrive

[iain reed]

hi all
any tips / traps for young players about fitting an overdrive to my 101.
many thanks to ron for everything. having cables made as we speak any getting a handle/lever thingy made now getting 2 done if you want on garry
got circlip plyers ready cleaned up the transfer case ready to go ... just thought i would ask the gang before i start ... wish me luck :)

[101RRS]

The easy bit is putting the o/d itself in. The hard bit is setting up the lever, cables, rear brackets on the gearbox and modifying the winch bracket to fit under the o/d.

Thanks for the offer of a cable but I had all new ones made last year - including for the O/d.

I would use the winch lever in its current position to operate the O/d - suitably modified - cut off the micro switch arm and extend the lever to just a bit longer than the hi/lo range lever and make up a new flat winch lever and move it over to the passenger side - you will need to weld the micro switch arm on this lever so - it will still work fine.

This way you will have the levers you use the most closest to you. Closest will be the O/D lever (the longest one), then next across is the Hi/Lo lever (unmodified) and furtherest across (and the shortest) is the winch lever. That way you do not have to stretch across the cab to change the O/D.

Also on the brackets and levers on the O/d itself, I found room under the floor was a bit tight. The activating arm that the cable connect to can be set up so it sticks up or sticks down. Because of the space problem I set mine in the down position - this means the lever in the cab is pushed forward to engage O/d. If I remember correctly Ron has his rear bracket in the top position so he pulls back on his cabin lever to engage O/D. Either is fine - personal preference I suppose and depends on how much insulation you have under your gearbox floor cover.

Cheers

Garry

[iain reed]

thanks for that ... i am having two levers made up to match the transfer one but a bit taller let me know if you want it

[101 Ron]

https://www.aulro.com/afvb/images/imported/2010/09/928.jpg
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[101 Ron]

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[101 Ron]

https://www.aulro.com/afvb/images/imported/2010/09/927.jpg

[101 Ron]

Hi Iain
See in the pics you will need a plate and ball swivel set up to go with the O/D cable on both ends of the new cable.
con wire will supply them , but you will have to nicely push them to do so as they order them in special.
Run the extra cable as per the pto and transfercase cable around the engine.
I use a old series landrover yellow 4wd knob for the O/D lever.
Only use the O/D in 4 th gear as using it in lower gears may over torque it and break it and there are no spares and parts and bearings for it are non standard.
The pto/winch cable will interfear with the overdrive slightly and how you handle that is up to you.
I as in the pics you can see I made a special alloy anchor bracket for the pto/winch cable.
Forward position of the overdrive lever is direct drive and pulling the lever back drops you though neutral and then into overdrive.

[101 Ron]

https://www.aulro.com/afvb/images/imported/2013/06/1253.jpg

[101 Ron]

These are con wires own notes.
Pass them on as it will help them greatly and ensure they will not stuff up your new cables.
https://www.aulro.com/afvb/images/imported/2013/06/1250.jpg
https://www.aulro.com/afvb/images/imported/2013/06/1251.jpg

[101 Ron]

The overdrive and transfercase both run engine oil.
They share their oil and this helps overdrive cooling.
top up transfercase first and leave oil level plug out.
Next fill up the overdrive to its level plug.
Any excess in the over drive gearbox will run out though the transfercase level plug.
refit transfercase and overdrive level plugs.
I tend to run molybond/Proma type additives to help things a bit.
Do not add any additive which thickens the oil like Nulon or Lucas.
I made up a alloy plate which stops oil leaking out of the overdrive when hot from the countershaft which protrudes though the overdrive housing.
https://www.aulro.com/afvb/images/imported/2010/09/919.jpg
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Let us know what you think of the overdrive in the 101.
You should find you can keep the power on for longer going down a hill and greatly reduce the front tailshaft buzz.
Ron

[101 Ron]

Another tip is to drill extra clevis pin holes in the lever for the cable on the overdrive(you can just see it in one of the pics) as it gives you different options for cable travel and leverage.
It can be done on the overdrive handle/lever in the cab too.( I made a cardboard one first and and sort of worked out where I needed to drill the hole for the clevis pin)
I found when I repositioned the cable for the Winch /pto slightly for the overdrive I needed to drill a extra hole in the lever for the pto coming out of the transfercase too to get things just right again.
When you do your overdrive cable run from the bottom of the radiator tunnel to the transfercase try and make the bends and curves in the cable little in number and large as possible as this will drop fiction in the cable.

[123rover50]

Where are you guys getting your winch drive from?
I cant see one of those bottom chain drive hens teeth in the pics.

[101 Ron]

The winch drive is a unique set up for a 101 landrover.
The 101s winch is mounted on the LHS chassis rail.
It is driven from the bottom of the transfercase via bevel gear set.
A short double uni joint takes the drive to the winch.
The overload clutch is built in the winch itself.
This system will not fit or work on any other landrover and is totally different to the army perentie landrovers, as the the winch is unusual too.
The 101 winch is one of the best around and very fast too.

[101RRS]

I cant see one of those bottom chain drive hens teeth in the pics.

The 101 pto is gear driven and goes out the side of the bottom of the tfr case.

A normal LT95 pto is chain driven and goes out the front of the bottom of the tfr case.

Garry

[iain reed]

:)Thanks for the photos of the transfer case cable adapter, cool should get cables this week and will get yours back to you. Just quick one ... Engine oil in transfer case not gearbox oil ? Is that right or Am I mad ... Getting some levers made

[101RRS]

:)Engine oil in transfer case not gearbox oil ? Is that right or Am I mad

Engine oil (20w40, 20w50) in the engine, gearbox and transfer case/overdrive.

You are correct but still a bit mad;).

Garry

[123rover50]

The 101 pto is gear driven and goes out the side of the bottom of the tfr case.

A normal LT95 pto is chain driven and goes out the front of the bottom of the tfr case.

Garry

I learn something every day. I have the chain driven one on the 6x6 driving a hydraulic pump for the winch.
I would like something for my 2B. Are these 101 PTO,s available or just as scarce as the chain drive ones?

[101RRS]

I would like something for my 2B. Are these 101 PTO,s available or just as scarce as the chain drive ones?

Of course the LT95 PTOs will not fit a series tfr case unless the 2B has been changed to a LT95. The point at the top of the tfr case where the overdrive goes in can still be used as a PTO for a rear drive (I guess like your 6x6 has). In the 101 this was the drive takeoff point for the powered trailer.

I guess the 101 bottom PTOs are exceptionally scarce, probably more so than the chain drive ones. In Aust there would have only been enough to service the 50 units on Aust 101s. On overseas 101s the winch was only fitted to a minority of 101s so they are rare overseas. I know that some were brought into Aust by an importer but I believe they were snapped up pretty quickly.

Garry

[123rover50]

Of course the LT95 PTOs will not fit a series tfr case unless the 2B has been changed to a LT95. The point at the top of the tfr case where the overdrive goes in can still be used as a PTO for a rear drive (I guess like your 6x6 has). In the 101 this was the drive takeoff point for the powered trailer.

I guess the 101 bottom PTOs are exceptionally scarce, probably more so than the chain drive ones. In Aust there would have only been enough to service the 50 units on Aust 101s. On overseas 101s the winch was only fitted to a minority of 101s so they are rare overseas. I know that some were brought into Aust by an importer but I believe they were snapped up pretty quickly.

Garry

Sorry should have said my 2B has a 4BD1 and LT95.
Thanks for the info on the PTO.

[101 Ron]

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[iain reed]

Hi all.
Inspired by the expo and a quite monday arvo ,game on on the overdrive adventure. All going to plan unit Fitted all good hang on to the shaft for dear life so it won't go back. Worked out transfer gear cable fitting no dramas all good. Put it all together, even put lots of oil in. (not gear oil ). The only problem is that it is a bit grumpy going into first. Who knows ? Other wise all good Maybe a bit of time to settle?:)

[101RRS]

The only problem is that it is a bit grumpy going into first.

Hmmm - overdrives don't have 1st gear so that might be your problem :o.

:D

Garry

[iain reed]

Bugger!!! Maybe the old girl will settle down. Lots of work this week so Monday is next play day

[101RRS]

Clutch in - smooth movement of the lever - slight pause in neutral to let the O/d synchros to catch up and all should be alright.

Is the O/d crunching or is the action just stiff. Sometimes I have to double clutch mine - particularly when moving out of O/d.

The lever and cable will initially be tight until it starts to wear in - it took a week or two for mine to bed in and the cable and linkages required multiple adjustments.

Garry

[iain reed]

Here is hoping Wish me luck :)

[iain reed]

finely a day off!!! got the lever sorted out , the bracket for the cable and.... it works ... you cant hurry thing will get pics soon
:)

[Lotz-A-Landies]

Photos and the work on the one day - wouldn't be insisting on that! :D

So far it has taken me 3 months (from the start of stripping down) to get the time to do the CV conversion and brake overhaul on Gog. The RHS is complete but the LHS needs the brake shoes and hub refitted, but another lost weekend just gone moving other things.

All was not completely lost as I did get to drive Wazza the Mk3 and nearly got it bogged. :o

Diana

[iain reed]

Cool at least you didn't get bogged. I had a 15 tonne hi ab with trailer with 3. 6 tone Gennys on board in the middle of Hyde park. Bummer as the council was watching had to get a retriever semi tow truck to get it out , fitted the gun clips in the 101. And am getting the tilt fixed this week getting the old girl ready for summer. Talk soon :)

[Lotz-A-Landies]

The mud was over the hubs of the trailer wheels! :(

Thought we'd have to use Wazza's winch and don't even know if it works yet. Then we thought it would pull over the shed before it got us out of the bog. :D :D

[101RRS]

And am getting the tilt fixed this week getting the old girl ready for summer. Talk soon :)

Those straps that had sun rotted through and then broke?

My 101 is kept outside and I am concerned that the tilt is not going to last long in Canberra's hi UV environment - in the 18months I have had it on it has started to get lighter in colour on the top and some of the side straps are starting to fade.

It is getting close to having to having the water proofing re-applyed but I am not sure if this helps with UV, fading and rotting caused by the sun.

So does the O/d work OK - I found that I had to adjust the cable a few times after installation as the cable stretches just a little and some of the fittings adjust position.

Good luck with it.

Garry

[101 Ron]

The overdrive will open up a whole new world with slightly better fuel burn and the long legs for the long trips.
I find my overdrive changes striaght into overdrive very well and quickly with the syncros working well.
Going from overdrive back to direct drive is a slower process with the syncros still working well , but a bit of time is needed to let the shift go though.
My detent ball adjustment on the overdrive could need to be slacken off a bit to free things up.
I find in practice around town I dont bother with the overdrive and only use it in 4th gear only after I get the old girl rolling along a flat open bit of highway.
When in overdrive I tend to leave it in long as possible and let the vehicle find its own speed up and down the hills( unless garrycol is behind me....then I will open the old girl up and try to demoralise him in his 101).

[Lotz-A-Landies]

Those straps that had sun rotted through and then broke?

My 101 is kept outside and I am concerned that the tilt is not going to last long in Canberra's hi UV environment - in the 18months I have had it on it has started to get lighter in colour on the top and some of the side straps are starting to fade.<snip>Garry

My SIII FFR is also kept outside so in an attempt to keep the tarp lasting as long as possible, it gets tarped up with one of those silver plastic jobbies when it gets home. In fact I place a cotton canvas tarp over the FFR then place the plastic one over and wrap up the whole car.

It is better to replace a $50 plastic tarp every 12 months than have to find another original FFR tarp.

Diana

[101RRS]

When in overdrive I tend to leave it in long as possible and let the vehicle find its own speed up and down the hills( unless garrycol is behind me....then I will open the old girl up and try to demoralise him in his 101).

:mad: - so where have you been hiding Ron - we haven't seen you online for a while.

[101RRS]

Garry

My SIII FFR is also kept outside so in an attempt to keep the tarp lasting as long as possible, it gets tarped up with one of those silver plastic jobbies when it gets home. In fact I place a cotton canvas tarp over the FFR then place the plastic one over and wrap up the whole car.

It is better to replace a $50 plastic tarp every 12 months than have to find another original FFR tarp.

Diana

Yes - I agree - I have a large caravan cover that I sometimes use but it is difficult to get on over top of a 101 - also my truck gets used a couple times a week (I put more kms on the 101 than my daily driver last FY) so it is a pain to put in on and off - I am thinking about buying one of those temp garages you can buy from Super Cheap to park it in.

Garry

[Lotz-A-Landies]

You need a cone of silence tarp that comes down from the sky when you park the 101 up! :D

[drifter]

Yes - I agree - I have a large caravan cover that I sometimes use but it is difficult to get on over top of a 101 - also my truck gets used a couple times a week (I put more kms on the 101 than my daily driver last FY) so it is a pain to put in on and off - I am thinking about buying one of those temp garages you can buy from Super Cheap to park it in.

Garry

Out in Mitchell there is a guy who sells caravans. He has a really old one in there as a 'museum piece'. It sits under one of those Super Cheap temp garages.

He reckons they are brilliant - as long as you are prepared to replace them every 6 months or so.

Might be just the ticket for you.