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Old 03-25-2015, 07:28 AM
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Fearthepack Fearthepack is offline
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Join Date: May 2012
Location: Orlando, Fla.
Posts: 236
Newbie finds 1/8 clearance for tranny repair

Just wanted to share my first time tranny removal and reinstall. I removed and re-installed my counter shaft with gears a dozen times to get procedure down to just minutes.

Worries
1. Does everything have to stay exactly as it is as the cover is taken off...in other words how much can i spin the gears, shift, play move stuff around and it not effect a damn thing... unlike trying to keep everything lined up for correct timing... so everything will go back into its place upon reinstall.

Answer
1. Play all you want. All the gears mesh together so if installed correctly on the shaft they only go in one way. In fact rotating the primary shaft seems to unload some meshing pressure on both removal and install. To be honest I thought nothing could be moved, rotated or everything would be messed up upon reinstall.

#3 Shift fork (the one furthest away from 5th gear) is not your friend. It is in your way on both removal and install.

Counter shaft with gears always gets jammed the last 1/8 inch before coming out and during install. Hell yeah that is frustrating.

Fifth gear hard to get off and on just rotate primary shaft slightly it comes right off and right on after that.

Lets reinstall counter shaft with gears best procedure is as follows:
1. Set the counter shaft with gears installed into case and very important get #3 fork engaged in its place on the shaft.... Now if you try and install you will be 1/8 off and jammed. Crap why why why? You MUST let the driven gear and 1st gear slide almost off the end of the shaft and 1st gear must slide off its bearing that creates the 1/8 inch clearance you need and allows the entire shaft to drop down and line up with hole in case. Now get 1st gear bearing slid back into place and with #3 fork still engaged slide the shaft all the way in opposite #5 gear. Rotating primary shaft if any slight binding occurs will always be your friend.

Removal best procedure is as follows:
1. Slide fifth gear off if binding rotate primary shaft
2. Keep #3 shift fork engaged onto counter shaft and start sliding counter shaft towards fifth gear, when driven gear and 1st slide almost off the shaft and 1st gear off its bearing this will create the 1/8 clearance and now completely remove the counter shaft with gears. Remember any slight binding can be overcome by turning primary shaft.

Conclusion: Finding the 1/8 clearance and how to duplicate it over and over made the job so easy, with out the 1/8 clearance it just binds and curse words will soon follow.

Hope this helps any and everyone.
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