So I got all the parts to fix the transmission and its back together, well except for the case cover. Are there any tips or tricks to get all the pieces to line up so it goes back together? Seems the shift fork shafts are the items causing the most issues. So far been about 2 hours and I can't get this cover back on. Thanks in advance.

 

If the cases are parted from different machines a lot of the times the holes don't want to line up. Even if the cases are a matched pair I've had the same problem on several over the years. Look at where the shift forks are hitting on the case holes on the opposite case. Should be an indention in the aluminum to where you can take a dremel tool if need be and slightly ream the hole out a tad. Drastic measure but at times it's what you have to do. Once the cases are together and bolts tightened,use a pair of vice grips on the belcrank to see if the gears shift ok. You may have to have someone turn the transmission shaft while you check the gears.

 

Thanks for the response. My cases are not matched as one of the issue was the cover was cracked due to one of the lugs of the engagement dog breaking off and the big gear shoving the piece through the case.


But if you've had these issues then I guess a newbie like me probably won't win the lottery and they drop together. I did hit each hole lightly with a chamfer tool to try to help but it sounds like a bit more may help. It was already quite a puzzle to get all the pieces to go back into the case, sure not like they fell out.


Off to the garage to give it another try and throw a few choice words at it.