Gearset change questions

[Chameleon90]

Thanks to another post, I have some of my questions answered, but not all of them.  I have a 90 FLHTC that has had a false neutral between 4th & 5th for years so I gought a gearset from an 02 Softail from a friend that was putting in a 6 speed.

1.  How hard is it to remove the bearing in the case after removing the 5th gear?  I don't have a press of any kind and would prefer not having to take the case off the bike.  Can I use a deadblow hammer and socket large enough to hit the outer edge of the old bearing?  After taking it out, can I freeze the new bearing and then use a propane torch to heat the case to get it back in? 

2.  Will the trapdoor from the Softail work on my case or will I have to remove the set and put it on my trapdoor?   

Thanks!

[gryphon]

The trapdoor will fit. The main thing would be if it was missing any mounting ears that are on your stock one. I would not go pounding on the bearing or the main gear either. Bust the case and you're screwed. They make a tool. I just sold one of those presses. Georges garage also makes one. buy the tool and after you're done with it sell it on ebay.

[hotroadking]

Yes you can knock main gear out but you risk damage to the case. Make a press up with threaded rod big washers some pcv pipe

Freeze the bearing it should pop right in without heating up case


Sent from my iPhone using Tapatalk

[smittyon66]

While you are that far into the trans, I'd highly recommend you install the Baker Anti-overshift Pawl. It will do a lot to improve your shifting, and it will also replace that 50 cent spring that has caused so many people grief.

http://www.bakerdrivetrain.com/drivetraincomponents/big-twin-racing.htm#antiOvershift

[Chameleon90]

I have the shift drum, forks and shifter pawl from the 02 which has the rectangular spring that the Baker talks about so I will be changing the shifter shaft bushing since it is lonter than the old one.

I will look for that bearing removal tool too.

Thanks again.

[gryphon]

You don't have to replace the shift shaft bushing. Buy a new one, cut approx. 1/4" off of it and slip it (the 1/4" piece) over the shaft before you install it. Works just fine. And you're right. The new shifter pawl and the Baker pawl are pretty much the same. I believe the Baker was made as an upgrade for the earlier tranny's. If you have a late style tranny top cover use it and it should keep your neutral light from coming on in 5th. Also, make sure you use the later style neutral switch. Otherwise the light will be out in neutral and on in any gear. For some reason the parts books don't show the shiftshaft bushing. It is part #34979-00. Good luck, it's a very worthwile investment.

[FSG]

Shifter Shaft Sleeve & Tool

[gryphon]

That's a lot less then I would have expected for the tool. Of course you'll probably only use it once in your life. could probably sell it for close to what you paid for it though. Never could figure out why that sleeve is not listed in any parts manuals. If I didn't go in armed with the part number I probably wouldn't have been able to get it.

[Chameleon90]

I went to the dealer to confirm parts availability for when I get paid and the person wanted to get some info from one of the Master techs regarding the shifter shaft bushing since I forgot to take the part number 34979-00 with me.  The tech came out and said that putting an 02 gearset in a 90 case will not work because the detent will be in the wrong place.  I might be remembering something wrong, but it had something to do with the detent and a change they made in the case in either 91 or 94. 

It will really piss me off to have spent all this and then it won't work in my 90 without having to change the case too. 

Anybody heard of a change to the gear case or would this have something to do with it?  http://harleytechtalk.com/htt/index.php/topic,38340.0.html

[Chameleon90]

Oh and they told me I have to change to the new style front pulley too.  $243 for theirs.

[gryphon]

According to my parts books, at least until 1995 the shift drum and supports carried a -79 suffix so no change there till probably '98. My softail case had an -89 suffix and I had no problems installing '02 tranny internals. As far as the pulley goes, they did make a change in '94 (I think it was '94). However to the best of my knowlege as long as you use the early seal and spacer you will be able to run your earlier pulley. Maybe the tech thought you were only changing the gear set and not the whole internals. There was a change in the mainshaft in '90 when they went to the splined shaft. This was an orphaned year as it changed again in '91. As long as you have the splined shaft (which you should) you're good there. I am not doubting the techs knowlege, he may just have misunderstood what was going on. I have however had certified tech's tell me stuff that was completely wrong.

[smittyon66]

FWIW, I just grabbed my Jim's catalog and took a look. They list complete gear sets available that fit 1990 - 2006 (std ratio pn# 8015).
Then I grabbed my V-twin catalog and it states that
"*Note: 1994-up gears can be used in earlier transmissions but only in matched sets."

I agree with gryphon. I think it will work, since you are changing the drum and supports along with the gear set.