I have a 1999 scrambler 500 4x4. My chain broke and I put a hole in my tranny case and broke a gear in the tranny. I replaced the gear and got everything back together. I have a terrible noise - sounding like it is coming from the clutch on the end of the tranny shaft. It only makes a racket when it is decelerating or when the engine braking system is working. I know the driven and drive clutches are good - I swapped them out with a buddy. My question is, is there some way I could have possibly got the tranny out of alignment with the front clutch? Any suggestions would be helpful. I know the noise is not coming from inside the tranny. Could the belt have possibly stretched and making a racket on deceleration? Please help, I am pulling my hair out.

 

Yes you could have gotten the tranny out of alighnment with the motor and causing the belt to make noises. The distance between the 2 shafts, Crankshaft and Trans. shaft should be 10". Get it as close as possible to 10" and you will probably solve that problem. If it was way off though, you could've also stretched the belt.

 

how can you adjust it?

 

Well, you will probably have to either take the tranny bolts loose and try to move it, or you can shim the tranny bolts, Or you can also move shims on the motor mounts? Why is it off? How far?? It would be a very good idea after you get the shafts right to go to your dealer and borrow a clutch alignment tool or buy one and check the alighnment of the sheaves. It is very important for the clutches to be lined up properly. The actual distance between shafts should be 10" + .1 inch to -.05 inch. But like I said, even after you get the shafts right, the sheaves could still be off a little, there is only 1/8 inch play with them.

 

I just put new bearings in my tranny and I too am getting a noise. I cant figure it out. Let me know how you make out maybee it will help me> Im going to check on the distance between then tonight.