5th Gear Swap How-to
The procedure for swapping out the 5th gear is rather simply. In short all you have to do is remove the end cover of the tranny, remove 2 retaining bolts, remove both the gears, put on the new gears, replace bolts and end cap, refill with gear oil and you are done. Sounds simple enough right? It basically is except for the removing of the original gears, thats where things get tricky…
You have 2 gears to remove, The larger drive gear with the associated selector assembly and the smaller driven gear. The smaller gear along with the selector are both pressed onto a splined shaft. So to remove both of these you will need a gear pullers. For the selector assembly any gear puller about the right size should work without issue but for the smaller gear some modification might be needed as the case is pretty close to the gear which makes getting the puller arms around the gear a little challenging. Once you get the puller on you will want to heat the gears so they expand as this should make the removal a little easier.
At about this point you would reach the scary part of the project. Once the puller is on the gear selector assembly and you are cranking down on it, it can take A LOT of force to get the gear office. Mine let out a loud crack which fortunately was the gear coming off the shaft. Ok, If that didn’t leave you horribly terrified here is the more detailed overview…
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