2023 Top Gear is Powdered Metal Junk

[EWK]

Small teeth engauged gives you fwd gear.

Thanks. Am I correct in that the reverse gear doesn't slide all of the way back onto those smaller teeth on the top gear during pre-assembly?

 

[Fords4life]

Thanks. Am I correct in that the reverse gear doesn't slide all of the way back onto those smaller teeth on the top gear during pre-assembly?

On reassembly make sure to slide the reverse gear fully over the small teeth of your upper sprocket, it will sit flush.

 

[EWK]

On reassembly make sure to slide the reverse gear fully over the small teeth of your upper sprocket, it will sit flush.

Thanks. That’s the clarity I was looking for. Couldn’t seem to get the reverse gear to fully engage the small teeth on the top gear but will go back at it tomorrow.

 

[Sevey]

On reassembly , that reverse gear needs to be pushed onto the 23t gear. You will feel it click or mesh together.
Ms

 

[74Nitro]

Why is it necessary to ensure it's in forward upon re-assembly?
I've often put them back together in reverse.

 

[cannondale27]

Why is it necessary to ensure it's in forward upon re-assembly?
I've often put them back together in reverse.

I dont think it matters other than to be sure it actually goes into forward and you dont have a shift fork or something on wrong. Most important is to go in and out of gear 3 times before moving to ensure that it finds home which is forward.

 

[Sevey]

Why is it necessary to ensure it's in forward upon re-assembly?
I've often put them back together in reverse.

Never considered putting it together in reverse. If it works - have at it.
Personally - i will continue reassembling status quo as i dont want issues when its all back together, for fear it has to be pulled apart again.
MS

 

[EWK]

Why is it necessary to ensure it's in forward upon re-assembly?
I've often put them back together in reverse.

Here is what I experienced/learned today when installing new Hurricane top gear - posting the details as it may help someone else.…and I’ll probably forget the details so it will help me as well for next time I get into the chaincase.
- watched all the videos and read the articles related to chaincase maintenance and top gear replacement so I went into this with confidence.
- everything went as expected until re-installing the reverse gear/fork assembly
- I could not get the top reverse gear to slide onto the smaller teeth of the new top gear. Would not go. No way - no how. I figured if I couldn’t force it to go back no way would the actuator motor get it to go.
- removed and tried the reverse gear on the stock 21T on the bench and it falls onto the smaller teeth section. Wtf.
- Disassembled everything - removed the new top gear to the bench and again - the reverse gear falls onto the Hurricane gear - same as stock. So the new gear is good. Wtf.
- put the Hurricane top gear back on and all of the other gears back on.
- still cant get the reverse gear to slide all of the way back onto those lower teeth. No way - no how. WTF.
- tighten the chaincase adjuster bolt to finger tight plus 1 turn back to take that out as a variable - no difference.
- take the reverse gear off and rotate it 45 degrees or so and notice that now I can push it all the way back but it’s not smooth and there is some interference.
- keep removing and rotating the reverse gear and eventually find a spot where it falls onto the top gear with no interference - all the way back.
- mark it with a sharpie - remove and reinstall with the reverse fork assembly.
- goes onto those smaller teeth now smooth as butter.
- make sure reverse gear is all the way back on the 21T and the rods on that assembly are all pushed back.
- install chaincase/oil tank cover. Torque screws to 9 ft lbs.
- fill chaincase with oil
- Grease and install reverse gear actuator. Notch down - slides right in. try to turn it ccw and it won’t rotate that way - good.
- install spring and detent block.
- rotate track by hand and confirm secondary is moving with track.
- prior to installing actuator motor I turn the actuator clockwise a bit - engage actuator motor - rotate motor ccw and can’t get holes to line up.
- after multiple tries - I turn actuator a little more than I think what 20 degrees looks like.
- engage actuator motor - rotate ccw - holes line up perfectly- actuator motor is in the same position as in the pics I took prior to dissembling.
- install screws, guard, everything else.
- start sled - warm up - everything works perfectly. Cycle between fwd and reverse 5 times - everything goes smooth - no weird noises.

Cant explain why reverse gear wouldn’t engage top gear until I rotated and found the sweet spot. Makes no sense to me. But everything is back together - working as it should and put away til the fall.

Hope this info helps someone else.

 

[74Nitro]

I dont think it matters other than to be sure it actually goes into forward and you dont have a shift fork or something on wrong. Most important is to go in and out of gear 3 times before moving to ensure that it finds home which is forward.

If it was taken apart due to a shifting issue then that would make sense for sure.
Otherwise, no difference that I can see.

 

[WinderFab]

Here is what I experienced/learned today when installing new Hurricane top gear - posting the details as it may help someone else.…and I’ll probably forget the details so it will help me as well for next time I get into the chaincase.
- watched all the videos and read the articles related to chaincase maintenance and top gear replacement so I went into this with confidence.
- everything went as expected until re-installing the reverse gear/fork assembly
- I could not get the top reverse gear to slide onto the smaller teeth of the new top gear. Would not go. No way - no how. I figured if I couldn’t force it to go back no way would the actuator motor get it to go.
- removed and tried the reverse gear on the stock 21T on the bench and it falls onto the smaller teeth section. Wtf.
- Disassembled everything - removed the new top gear to the bench and again - the reverse gear falls onto the Hurricane gear - same as stock. So the new gear is good. Wtf.
- put the Hurricane top gear back on and all of the other gears back on.
- still cant get the reverse gear to slide all of the way back onto those lower teeth. No way - no how. WTF.
- tighten the chaincase adjuster bolt to finger tight plus 1 turn back to take that out as a variable - no difference.
- take the reverse gear off and rotate it 45 degrees or so and notice that now I can push it all the way back but it’s not smooth and there is some interference.
- keep removing and rotating the reverse gear and eventually find a spot where it falls onto the top gear with no interference - all the way back.
- mark it with a sharpie - remove and reinstall with the reverse fork assembly.
- goes onto those smaller teeth now smooth as butter.
- make sure reverse gear is all the way back on the 21T and the rods on that assembly are all pushed back.
- install chaincase/oil tank cover. Torque screws to 9 ft lbs.
- fill chaincase with oil
- Grease and install reverse gear actuator. Notch down - slides right in. try to turn it ccw and it won’t rotate that way - good.
- install spring and detent block.
- rotate track by hand and confirm secondary is moving with track.
- prior to installing actuator motor I turn the actuator clockwise a bit - engage actuator motor - rotate motor ccw and can’t get holes to line up.
- after multiple tries - I turn actuator a little more than I think what 20 degrees looks like.
- engage actuator motor - rotate ccw - holes line up perfectly- actuator motor is in the same position as in the pics I took prior to dissembling.
- install screws, guard, everything else.
- start sled - warm up - everything works perfectly. Cycle between fwd and reverse 5 times - everything goes smooth - no weird noises.

Cant explain why reverse gear wouldn’t engage top gear until I rotated and found the sweet spot. Makes no sense to me. But everything is back together - working as it should and put away til the fall.

Hope this info helps someone else.

Mine is the same way, first year with stock top gear I had to find the right spot to mesh the gears, last 3 years with the DMC top gear have been the same, I just mesh the gears before closing the case and never had a problem.

 

[hellflyer]

Turn the track to line it up. Chain turns with the track until that gear is meshed up!

 

[northwindwinder]

Just got a 22t top gear ( the good 0ne ) stock chain with 5500 miles hopefully stretched enough to fit. Or should I look at replacing the chain also

 

[number1kyster]

It will definitely be stretched enough to fit. You should be good to go.

 

[DMCTurbo]

Turn the track to line it up. Chain turns with the track until that gear is meshed up!

You beat me too it!

 

[hellflyer]

You beat me too it!

Or even better take the belt off and turn the jack shaft! Lol