2007 Phazer will not stay in drive

[gdh]

I have a 2006 phazer. I have taken it into a shop twice because it keeps "jumping out of drive"(or at least that is what it feels like). It will go in and out of reverse just fine, but when running in drive, it makes a loud clacking sound and it feels like the drive disengages. The repair guy said the first time, there wasn't any oil in the crank case, he replaced a seal (small device that gets oil into the gear box). Same thing happened. Back in the shope the second time, he said it was the actuator (can't find this name on any exploded diagram but the mechanism that actually switches from drive to reverse) and he put in a used one. Now it shifts into reverse and drive easier than before, but after running about 1/2 mile, the clacking started up again. Getting back to the truck, it seems to jump out of gear more if it was going up a hill. Does anyone have any idea what would cause this?

 

[Mooseman]

Are you certain about the year? Yamaha didn't have a 4 stroke Phazer until 2007. If it is a 2007+ Phazer, sounds like the problem my son had with his 2009 Phazer. It was like it was skipping in forward gear making an awful noise. It likely lacked lubrication and some of the the internals have been damaged like this one:
http://www.ty4stroke.com/threads/reverse-gear-box-inspection.123019/

We wound up finding another complete reverse gear box.

 

[gdh]

Mooseman-Thanks for the link (and for reminding me my sled is actually an 07-guess that shows how new to this game I am). That link almost exactly describes my problem. My filler tube failed and probably was the cause of the problem to start, although it sounds like there were some issues from the factory with the original assembly with some gear boxes. Thanks again for your help.

 

[Mooseman]

If you mean by "filler tube" the little one that looks like a pipe that feeds the reverse gear, yes, it has been the cause of a few failures. The new part has a longer tube and seal.