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> There sure are a lot of parts in a 901 box, Now I'm going to try to put them back in
DNHunt
post Nov 6 2005, 12:52 PM
Post #81


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Next, 2nd, 3rd shift rod! These bolts are only hand tight right now cause I'll adjust them later.


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DNHunt
post Nov 6 2005, 12:53 PM
Post #82


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Next is the little peanut thing in the tube in the intermediate plate.


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DNHunt
post Nov 6 2005, 12:56 PM
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After you shove it in you should be able to just barely see it through the 1st, reverse shift rod hole in the intermediate plate.


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DNHunt
post Nov 6 2005, 01:00 PM
Post #84


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Next the 1st, reverse shift rod and shift fork go on with the bolt finger tight.


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DNHunt
post Nov 6 2005, 01:01 PM
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The 3rd and final ball goes in the tube


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DNHunt
post Nov 6 2005, 01:02 PM
Post #86


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Then the stiffer of the 2 springs


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DNHunt
post Nov 6 2005, 01:03 PM
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You can see the last spring in the hole


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DNHunt
post Nov 6 2005, 01:04 PM
Post #88


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The plug finishes it up


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DNHunt
post Nov 6 2005, 01:04 PM
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Done with that


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qa1142
post Nov 6 2005, 01:09 PM
Post #90


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Very cool stuff
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DNHunt
post Nov 6 2005, 01:18 PM
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This is a side shifter!!!

Adjusting the shift forks for 2nd, 3rd and 4th, 5th can be done now. The balls and springs will hold the shift rods in neutral and the alignment jig supports the free ends of the rods. You should be able to see all of the notches in the shift rods lined up. Like this


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DNHunt
post Nov 6 2005, 01:19 PM
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The jig holds everything nice and steady


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DNHunt
post Nov 6 2005, 01:23 PM
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Tighten the bolts when the sliders for 2nd, 3rd and 4th, 5th are centered between their respective gears. Here is what 4th, 5th should look like.


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DNHunt
post Nov 6 2005, 02:30 PM
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Haynes manual calls for 1mm clearance between the back of the slider and reverse on its' shaft. Once I got that I tightened down the bolt on the shirt fork then rechecked it.


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DNHunt
post Nov 6 2005, 02:32 PM
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The gear stack is now ready except for torquing the 30 mm bolt on 1st gear.


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DNHunt
post Nov 6 2005, 02:34 PM
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The paper shims for the intermediate plate were not colored and the replacements in the gasket kit are not either so I had to measure them. I chose a none compressed area in each. There are passages or something where the castings are not solid and the sealing surfaces do not compress the shims. The old ones added up to .015".


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DNHunt
post Nov 6 2005, 02:36 PM
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One old shim measured .009"


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DNHunt
post Nov 6 2005, 02:37 PM
Post #98


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The other old one was .006


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DNHunt
post Nov 6 2005, 02:38 PM
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It just so happens that there was an .009" in the gasket kit.

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DNHunt
post Nov 6 2005, 02:38 PM
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And lucky me an .006. I guess I'm good to go.


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