Borg-Warner Overdrive problems

[toolman8]

Hi guys,

I stumbled in here hoping that perhaps someone could offer their expertise. I actually have a 1929 Cadillac into which I have installed a Borg-Warner overdrive (Lloyd Young did the work, he's apparently quite well known for B-W overdrives). Anyway, it's mounted in the middle of the car's torque tube, not to the transmission, but I don't think that's relevant. The setup does not use a kick-down switch or governor, but rather a pushbutton to activate the overdrive. There's a microswitch on the clutch that deactivates the OD every time I stop or shift, and the freewheeling cable is still in place, so I only use it in 3rd gear at speeds above 30 MPH. When it works, it works extremely well.

I have several issues, and the overdrive itself has been in and out of the car three times ($800 each time because the whole torque tube and rear end have to come out) and Lloyd has rebuilt it twice. The symptoms are the same each time. When it's cold, like when I first start driving, it works properly. When it gets hot, like say, after a half-hour of driving, it stops working, and about half of the time when that happens it will go full neutral when I hit the button--that is, the engine won't drive the wheels and the wheels won't drive the engine. At that point, I have to stop, pull out the cable, and start going again.

It certainly seems to be heat-related, so I have wrapped the muffler and exhaust pipe in heat shields, and just today ordered one of those brand new (not used or NOS) solenoids thinking that the old one is getting sticky when it's hot. I am also having a custom exhaust system made to get the exhaust away from the solenoid, and even considered tack-welding some cooling fins to the solenoid itself. But I'm concerned that there is some damage being done, because the overdrive eventually fails entirely and no longer shifts, warm or cold, and I have to yank it out and send it to Lloyd to be rebuilt (again). I have also read that using the wrong lubricant can make the freewheeling rollers too slippery, and when I first started using it, I did put synthetic gear lube in it. Problem?

I don't have a very good knowledge of how these work, but I'm concerned that something related to the pawl inside that controls freewheeling and/or the pin that locks the planetary gears is being damaged by the "partial" engagements that make it go full neutral. I could swear that there's a grinding or ticking sound coming from the overdrive unit itself--it sounds suspiciously like a metal fuel or brake line dragging on the pavement as I drive, and at higher speeds, it's a whizzing sound. It could certainly be something else, but I don't trust the overdrive one bit. I read that they're quite durable and simple, but am I tearing it up by putting 100 horsepower through it without the solenoid engaging properly?

This is really wrecking my enjoyment of the car, because everything else works superbly and it really cruises beautifully when the overdrive is working. I'm just tired of being afraid to push the button and/or getting stranded when the OD fails.

I'd be happy to clarify any details, but if anyone with some expertise could help, I'd sure appreciate it. I don't want to tear it out again now that driving season is here.

Thank you very much in advance!

[toolman8]

More photos of the installation. The solenoid isn't quite as close to the exhaust as it looks in that photo. It's actually behind the muffler by a few inches, not nearly touching it. The new system uses a smaller diameter muffler and moves it about six inches forward. I will continue using the heat shields, of course.

Thanks!

[basshound71]

Don't know diddly about you issue but very nice car

[Donnie]

You say Lloyd has to rebuild it each time it fails??? I would ask HIM what is causing the failure, he has the best chance to come up with a conclusion, as he has a hands on position...........Donnie