If you had an AE there'd be no question -- they'd have to fix it free of charge while in warranty. May be one plus for owning an AE.
No, not fearless, desperate! Desperation leads to innovation. I couldn't afford the dealer's BS.Wow Scott, I am very impressed. Major job, you are fearless.
I just wanted to see what it looked like.May I ask what were the symptoms that led to the tear down?
But seriously, every time I went into 2nd gear, either from 1st or 3rd, and put the engine under even a mild load (up a hill, accelerate, etc), it would kick out of gear, re-engage, kick out, re-engage, etc for about 1 to 10 seconds before finally engaging. I now know that it was the engagement dogs partially engaging, disengaging, and catching on the next engagement area.Jumping out of gear? Missed shifts? Hard to find neutral?
Thank you for the symptom report. My 60k 06 A model will sometimes disengage 1st in a downhill corner after downshifting from 2nd. I've learned to 'double shift' down into 1st to be sure I don't hit that neutral at the exact moment I need engine decel.No, not fearless, desperate! Desperation leads to innovation. I couldn't afford the dealer's BS.Wow Scott, I am very impressed. Major job, you are fearless.
I just wanted to see what it looked like.May I ask what were the symptoms that led to the tear down?
But seriously, every time I went into 2nd gear, either from 1st or 3rd, and put the engine under even a mild load (up a hill, accelerate, etc), it would kick out of gear, re-engage, kick out, re-engage, etc for about 1 to 10 seconds before finally engaging. I now know that it was the engagement dogs partially engaging, disengaging, and catching on the next engagement area.Jumping out of gear? Missed shifts? Hard to find neutral?
So, from my very lay person's point of view, it appeared I somehow got a bent shift fork, and that lead to the engagement dogs wearing, which lead to the, at first, sporadic skipping described above. As they got worse wear, it became more frequent.
I received 95% of my parts today, the rest are back ordered. The ones I am missing are the lower shift fork, lower shift fork guide, 2nd gear wheel and 5th gear wheel.Scott,
What's the status on the parts you need to finish the repair? We are all watching and waiting with great anticipation. :clapping:
Burk
Ditto, you should get a set of those gnarly steel balls guys hang from their truck and put a set on the FJRPF -- I'm impressed. You are hereby promoted to "Stallion Stud" for taking on such a project. :clapping:
This thread is over three years old and l believe that life has taken 'fool in other directions, so I don't expect to see the pictures reappear. He did check in on 9/11 so there may still be a glimmer of hope.Dear Ponyfool...Could please repost the pictures in the beginning of the tread...
Exactly the problem I'm having !! You think if I studied some pics (if I could find any) long enough I'd absorb the knowledge to fix mine<!--quoteo(post=437167:date=Jun 18 2008, 04:23 PM:name=dcarver)--><div class='quotetop'>QUOTE (dcarver @ Jun 18 2008, 04:23 PM) <a href="index.php?act=findpost&pid=437167"><{POST_SNAPBACK}></a></div><div class='quotemain'><!--quotec-->Wow Scott, I am very impressed. Major job, you are fearless.<!--QuoteEnd--></div><!--QuoteEEnd-->No, not fearless, desperate! Desperation leads to innovation. I couldn't afford the dealer's BS.
<!--quoteo(post=437167:date=Jun 18 2008, 04:23 PM:name=dcarver)--><div class='quotetop'>QUOTE (dcarver @ Jun 18 2008, 04:23 PM) <a href="index.php?act=findpost&pid=437167"><{POST_SNAPBACK}></a></div><div class='quotemain'><!--quotec-->May I ask what were the symptoms that led to the tear down?<!--QuoteEnd--></div><!--QuoteEEnd-->I just wanted to see what it looked like.
<!--quoteo(post=437167:date=Jun 18 2008, 04:23 PM:name=dcarver)--><div class='quotetop'>QUOTE (dcarver @ Jun 18 2008, 04:23 PM) <a href="index.php?act=findpost&pid=437167"><{POST_SNAPBACK}></a></div><div class='quotemain'><!--quotec-->Jumping out of gear? Missed shifts? Hard to find neutral?<!--QuoteEnd--></div><!--QuoteEEnd-->But seriously, every time I went into 2nd gear, either from 1st or 3rd, and put the engine under even a mild load (up a hill, accelerate, etc), it would kick out of gear, re-engage, kick out, re-engage, etc for about 1 to 10 seconds before finally engaging. I now know that it was the engagement dogs partially engaging, disengaging, and catching on the next engagement area.
So, from my very lay person's point of view, it appeared I somehow got a bent shift fork, and that lead to the engagement dogs wearing, which lead to the, at first, sporadic skipping described above. As they got worse wear, it became more frequent.
Very few pics, but lots of reading ......................... brave guy that Ponyfool! I'm not in his league .. dealership for me I think.
I have saved the Pictures, 4 of them, let me know where I can send them so they can be viewed for future use.This thread is over three years old and l believe that life has taken 'fool in other directions, so I don't expect to see the pictures reappear. He did check in on 9/11 so there may still be a glimmer of hope.Dear Ponyfool...Could please repost the pictures in the beginning of the tread...
I successfully split the cases and removed the main drive shaft, shift drum assembly, and transmission this afternoon. Upon inspecting the parts, I can clearly see damage to the shift fork and gear dogs. So far, there hasn't been any "holy ****, now what?" issues. It's been pretty straightforward. Let's hope I think that when I am putting it back together.
See for yourself:
<b>Click Image to Enlarge</b>
<b>CASES SUCCESSFULLY SPLIT
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3152.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3152small.jpg" border="0" class="linked-image" /></a>
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3153.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3153small.jpg" border="0" class="linked-image" /></a>
DRIVE AXLE ASSEMBLY
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3156.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3156small.jpg" border="0" class="linked-image" /></a>
DAMAGED SHIFT FORK
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3159.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3159small.jpg" border="0" class="linked-image" /></a>
DAMAGED GEAR DOG
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3161.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3161small.jpg" border="0" class="linked-image" /></a>
ANOTHER VIEW OF DAMAGED GEAR DOG (All dogs on this gear (2nd) have similar wear)
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3162.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3162small.jpg" border="0" class="linked-image" /></a>
DAMAGED GEAR (WHERE DOG ENGAGES) and DAMAGED DOG</b>
<a href="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3163.jpg" target="_blank"><img src="https://www.ponyfool.com/pictures/fjr/engine_removal/IMG_3163small.jpg" border="0" class="linked-image" /></a>
UPDATE: The job is finished. Outlined in this thread: <a href="https://www.fjrforum.com/forum//index.php?showtopic=106625" target="_blank">https://www.fjrforum.com/forum//index.php?showtopic=106625</a>
Thanks 03HiYoSilver Copied and printed the info for my perusal. Hope it helps me at least understandI have saved the Pictures, 4 of them, let me know where I can send them so they can be viewed for future use.This thread is over three years old and l believe that life has taken 'fool in other directions, so I don't expect to see the pictures reappear. He did check in on 9/11 so there may still be a glimmer of hope.Dear Ponyfool...Could please repost the pictures in the beginning of the tread...
Your Welcome...here is a Closer Look at the Shift Fork:Thanks 03HiYoSilver Copied and printed the info for my perusal. Hope it helps me at least understand
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