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October 26th, 2012, 04:55 PM   #1
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I Ride: 1995 dakota 408 5spd 8 3/4 rear end
tight transmission

having a problem fitting case halves together on the gearbox side, seems to shift tight once bolted down,,

first i drop in the gear shafts with gears into the left hand case, fit in the drum and selector forks, turn the drum and it shifts nice up and down threw the gears and to neutral.....

then fit the right hand case and bolt it down finger tight (it goes together nice just a couple soft taps with a dead blow at the end to seat cases and everything)

when turning the clutch shaft to synchronize gears and shifting the drum will go up through the gears and into neutral and all seems free but after shifting through gears once up or once down, during 2-3? or 3-4? shifts up or down it will jam and then not want to go into any gears smoothly and also gets hard to turn the clutch shaft if not impossible to turn it by hand, can put clutch basket on and with the extra leverageget it to turn again by hand...

maybe a bearing not fully seated in case? or not spinning fast enough for proper synconization? switched around a shift fork position? i went back through the shaft with the parts manual and everything is in place, i also tried attaching the actual shifter lever but seems even harder with that on then with just turning the shift drum/star dirtecly with a small wrench.

it seems everythin free almost feels like a shift fork jamming but all is oiled and looks smooth.

shifted fine before tear down....maybe some has ran across this before. probably something dumb i am missing, will be going back to the shop soon to mess around with it some more

cheers
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October 26th, 2012, 10:51 PM   #2
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I Ride: 1995 dakota 408 5spd 8 3/4 rear end
Re: tight transmission

Ah i knew it would be something i did, actually mutlipe things, a thrust washer and a gear, the thrust washer i realized right away but accidently must have flipped the gear too at some point, the parts manual pic shows the slots on the out side so it looked normal....3rd times a charm , at least i realized all this on the test fit, crank end play is good and shifts nice and all feels sweet, now ready for some 3bond and a piston should be all down hill from here, i hope
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October 27th, 2012, 10:08 AM   #3
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I Ride: 1995 dakota 408 5spd 8 3/4 rear end
Re: tight transmission

hhhm... liner fitted, head torqued, cases sealed and torqued, shifting seems stiffer then the final test fit....it was perfect then. of course i didnt have the liner and head all torqued at the same time then just the bottom halves.

when shifting through the actual shifter lever it was not hard during test fit, now the same test it is slightly tight, everything is slightly tighter then test fit even turning of the shafts slightly more, now it still goes through all the gears with lever but sometimes almost wont turn it all the way and needs a little wrench to get it 'over the hump' it will go through all gears pretty easy with the small 10mm wrench right at the star wheel. maybe now my problem actually is not being able to turn the shaft and click it all into place correctly every time i bump the lever while spinning the shaft and is fine..

i could just be paranoid now...really dont want to have to take it back apart for something after this point
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October 12th, 2015, 07:15 AM   #4
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I Ride:
I know this is an old thread, but I have the same problem with mine. Did you run the bike? my shaft is also kind of hard to turn.
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