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  #111  
Old 1 Week Ago
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We apologise as we neglected to tell you one important little not-in-the-FSM hint - before pulling the trans out from the left side, tap the mainshaft on the right side with a rubber mallet [or equivalent tool] a few times to loosen things up. Then when you have started pulling it out tap it again. Next time

Try this - take pictures of the parts pile, put a number on each part [use Microsoft paint], post it here, we can attempt to tell you how it all goes together. Will be a useful exercise for all of us
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  #112  
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I did just that. Here's the pic, and I have the parts laid out just like that old 'loaner' trans and as per the FSM diagram. Right side is output side. left side is trapdoor side. I did recover all 23 rollers.



#12 is just a spacer. #1, 5, and 7 appear to be thrust washers.

Everything looks good. My only concern is that 2nd c/s gear - it's brown, while all others are silver/bare steel. My first thought was that it's burned, but the shaft and the mating gear are fine, no brown color. Here's a comparison pic of the other similar m/s gear -



I'm going to post that pic and description in the Transmission forum as well, to get as many opinions as possible.

What do y'all think???

Last edited by ferretface; 1 Week Ago at 17:46..
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  #113  
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Looks like the upper (silver) gear has some wear on the dog pockets?
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  #114  
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Quote:
Originally Posted by ryder rick View Post
Looks like the upper (silver) gear has some wear on the dog pockets?
I don't think so. Each pocket abutment has a slight bevel on the leading edge. There are some shiny wear marks, but they are on top of tool marks from the machining operation. IMO.
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  #115  
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Like I said it appears worn.
I don't know why the other gear is that color but I would choose that gear over the silver from what I see from this side of the interwebz.
That gear is not discolored from heat. Are there any stampings in it like AP? It may be a different alloy....
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  #116  
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Quote:
Originally Posted by ryder rick View Post
Like I said it appears worn.
I couldn't find a pic of an H-D 2nd m/s gear, but here's one made by Dixie with the bevels on the pockets -

https://www.ebay.com/itm/56-90-Harle...6/401189312904

Quote:
I don't know why the other gear is that color but I would choose that gear over the silver from what I see from this side of the interwebz.
That gear is not discolored from heat. Are there any stampings in it like AP? It may be a different alloy....
No markings at all. Could be a different alloy; could be different heat treatment. What's your opinion of both or either? If in doubt, replace it?
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Put them both in a box an use the one that rolls out first when you tip it!

They both have signs of wear but a lot I cant see in the pic.

Like the gear teeth, and how it fits on the splines and if the fork groove is worn and if the dogs on the other side are biffed.

I hope you have replaced both of the 20 tooth gears with Andrews... Or this all may be a waste of time and cases.
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  #118  
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Quote:
Originally Posted by ryder rick View Post
I hope you have replaced both of the 20 tooth gears with Andrews... Or this all may be a waste of time and cases.
The Andrews gears are the only reason I'm doing this. You came late to the party.
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  #119  
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Quote:
Originally Posted by ferretface View Post
ARGH!!! Disaster!!!



The trans did not come out as an assembly!!! The two shafts hung up in the case...Gears, shims, bearings all fell into the case...Only the trapdoor and the front stuff came out intact...



I'll never figure out how everything goes back together...............,,,,

You’ll figure it out. Use the FSM/Andrews site parts list/descriptions to figure out which gear is which & which way around they fit on the shafts, then use a sharpie to mark them all CS2/MS3 etc. Mark them left or right side too. Then play with how it all fits. If I got there you will too. Starting with a confusing pile of parts helps with figuring it all out.
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  #120  
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Quote:
Originally Posted by paulc View Post
You’ll figure it out.
Yep. Got it all assembled on the bench with the new 2nd c/s, 3rd m/s, and main c/r gears and a new mainshaft bearing (can't hurt) and new top hats. I have all four gears plus neutral. No parts left over.



The '83 trans had two .050" mainshaft tabbed thrust washers, and the countershaft had one .055" thrust washer. I haven't checked gear spacing yet, got the last of the parts today and just finished assembling them all. I don't recall reading here about checking the c/s thrust washers; have to look that up.

On initial disassembly, I was able to remove the clutch gear + bearing from the trapdoor and the gear itself from the bearing using my 1-ton Harbor Freight arbor press. Putting the new parts back together was easy - chilled the new gear in the fridge and warmed the new bearing over the oven vent. For installing in the trapdoor, I just chilled the gear + bearing and pushed it on with my drill press chuck. Went right in.

I'm wondering if there's parts in the tower that could stand re-freshening - the springs maybe???

Last edited by ferretface; 1 Week Ago at 04:56..
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