2nd gear sketchy

[redblk63]

Wilf,

You hit the nail on its head! That is what I needed to know. I rushed out to the garage, and after better cleaning found where there used to be a hole in the cover plate, now filled with 1/2 of the broken pin. I also found the other half of the pin. I'm now a happy man. I'll probably drill a new hole, unless I get lucky extracting the broken pin. All very doable. I'll post pictures when I can get the darned things onto my computer.

Next, to split the transmission cases.

Larry

[redblk63]

One picture shows the housing with planetary gears. Broken pin is at bottom of the housing (6 o'clock) with the hole visible to its left.

Other pic shows ring gear, with the hole at its outer radius that this pin goes into.

I plan to drill a new hole, and break off the bit to use for a new pin.

[redblk63]

Now for the good stuff!

Here are some pictures. I did not find anything glaring, but sure enough, there is some minor rounding of the 2nd gear dogs. Can someone with experience in transmissions tell me if that is causing the trouble getting into 2nd gear. Symptom is it pops out when I apply torque, sometimes popping out and then back in, ouch!

Seems like this could be the trouble, but not very dramatic amount of rounding.

[redblk63]

here are some pics of the forks and drum. The rollers that go into the drum look OK to me, but I am a novice at transmissions. Anyone see something bad here?

[Loudo]

I would say that is a "goodly" amount of dog wear. I had similar wear which was sufficient to cause the second gear mayhem you are describing. It's only going to get worse once they start slipping.

Without the parts being cleaned off a little better and a real plan view photograph of the shift forks it's hard to tell their condition. Take a good look at the gears that the forks manipulate back and forth, it's hard to tell if they are worn similarly. In the photo the outside rim looks very dark which could be the result of getting hot repeatedly. Mine looked like that too.

I note that in the second photo the shift fork looks like there's a crack or cracks in the body. As a minimum it might be advisable to replace that one regardless of what else you do. The "belly" of it looks burned also, mine was the same.

What is the condition of the 14mm copper bushing that resides under first gear?

[teazer]

Those dogs won't hunt.... They are as bad as any I've seen and are clearly a problem.

[redblk63]

Loudo, you have sharp eyes! I'll clean the forks and examine closely for that crack, and also to look for burned surfaces. May be Friday before I can get out to the garage again.

Teazer, that is what I wanted to hear. So contingent on shift forks, looks as if replacing 2nd gear will fix me up. Great news!