Had a breakthrough and learning experience today. I spent over an hour standing over the trans rotating it and trying to make sense of things. At first I thought I was looking at it in 1st when really it was in 5th and visa versa, and was totally looking at everything all wrong, including the pictorial in the manual. Well, once I started seeing this correctly I was able to take a better look at the actual gear in question and indeed it is rounded more than any of the others.
Pictured here in the Neutral position, gear #3's dogs are rounded as well as the female recessed areas of gear #1 that mate with #3's dogs.
Now I can see what would be happening and was kind of able to simulate it by not getting 1st gear all the way clicked in and rotating the countershaft while holding the gears on the mainshaft. I can only imagine what the actual force of the motor would do. However I still believe the shifter had something to do with not getting them seated together well and allowing for less engagement. I did notice that whatever shift fork is meshing 2 gears/dogs together for a particular gear position, that shift fork has the most allowable slop/movement side to side due to the pattern in the shift drum. So the gears can be anywhere from fully seating inside one another to only having a little less than an 1/8" engagement. This of course is worse when you have the male in the already smoother rounded female receptacle as opposed to the 2 male dogs engaging as in some gear selections. Now I see why some people talk about putting springs on the forks to pull them in together. So, now I gotta decide if getting the shifter pawl/detent plate setup correctly will be enough to fix it or if I should replace these two gears.
Anyhow, you guys nailed it. Thanks for working with me. More to follow.
Pictured here in the Neutral position, gear #3's dogs are rounded as well as the female recessed areas of gear #1 that mate with #3's dogs.
Now I can see what would be happening and was kind of able to simulate it by not getting 1st gear all the way clicked in and rotating the countershaft while holding the gears on the mainshaft. I can only imagine what the actual force of the motor would do. However I still believe the shifter had something to do with not getting them seated together well and allowing for less engagement. I did notice that whatever shift fork is meshing 2 gears/dogs together for a particular gear position, that shift fork has the most allowable slop/movement side to side due to the pattern in the shift drum. So the gears can be anywhere from fully seating inside one another to only having a little less than an 1/8" engagement. This of course is worse when you have the male in the already smoother rounded female receptacle as opposed to the 2 male dogs engaging as in some gear selections. Now I see why some people talk about putting springs on the forks to pull them in together. So, now I gotta decide if getting the shifter pawl/detent plate setup correctly will be enough to fix it or if I should replace these two gears.
Anyhow, you guys nailed it. Thanks for working with me. More to follow.
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