4spd popping out of Third

[Jonas]

I have a 1981 FLH. The transmission will pop out of third gear. I have orderd a Shop Manual for the bike and plan to pull the transmission soon.

Little History of the problem. (This was my brother's bike)

The problem started after he had the transmission rebuilt. He pulled it, took it back to the guy. After putting it back in the bike it did not take long before the problem started again. The problem got progresivly worse. The rebuilt transmission has less then 10K miles on it.

Any help or suggestions are appreciated.

[springer-]

That transmission is what's called a "Cow Patty". It uses a rotary shift mechanism instead of a drum. The slots can become worn and allow the transmission to not engage the gears fully. Another problem is with the hats on top of the shift forks becoming worn or using the wrong ones or not there at all. The shift fork adjustment could also be a problem. Not to mention the dogs on the gears could be worn and slipping out of gear. It will likely be some form of the dogs not engaging fully. You don't need to remove the transmission to check these things. Feel free to contact me if you need some help or pointers.

[Jonas]

Originally Posted by springer-

That transmission is what's called a "Cow Patty". It uses a rotary shift mechanism instead of a drum. The slots can become worn and allow the transmission to not engage the gears fully. Another problem is with the hats on top of the shift forks becoming worn or using the wrong ones or not there at all. The shift fork adjustment could also be a problem. Not to mention the dogs on the gears could be worn and slipping out of gear. It will likely be some form of the dogs not engaging fully. You don't need to remove the transmission to check these things. Feel free to contact me if you need some help or pointers.

Springer, Thanks.

I will be contacting you

[Hillside]

Originally Posted by Jonas

Springer, Thanks.

I will be contacting you

Chances are the cat never set the fork spacing correctly, now the shift clutches, have become buggered on the edge, and won't stay locked in.
It ain't gonna get better.
We've built so many of those gearboxes over the years, we can do them in the dark, upside down.
Use to run that same trans in our AHDRA Mod bike. Sent that bike down the track at under 9 seconds many times.
Scott

[Jonas]

I got my manual today and have been reading about the transmission.

My first question. Should I just plan on buying the Gauge for the shift forks?

Here is picture of the bike

[springer-]

Originally Posted by Jonas

I got my manual today and have been reading about the transmission.

My first question. Should I just plan on buying the Gauge for the shift forks?

Here is picture of the bike

I wouldn't until you get in there and see what's going on.

[Jonas]

Originally Posted by springer-

I wouldn't until you get in there and see what's going on.

Makes sense

I rode it a little this weekend. It does not take long for it to pop out of third. If I short shift from third to fourth. I can ride it. I tried to rest my foot on the heel part of the shifter to keep it from popping out. Made no difference

All other gears seem fine. Hopefully oneday this week I can pull the top off and have a look.

Thanks Springer

[dieselman66]

Originally Posted by Jonas

I have a 1981 FLH. The transmission will pop out of third gear. I have orderd a Shop Manual for the bike and plan to pull the transmission soon.

Little History of the problem. (This was my brother's bike)

The problem started after he had the transmission rebuilt. He pulled it, took it back to the guy. After putting it back in the bike it did not take long before the problem started again. The problem got progresivly worse. The rebuilt transmission has less then 10K miles on it.

Any help or suggestions are appreciated.

hi i am sure that they put the 220: MAINSHAFT, CLUTCH
that goes between 3and 4 gear in backwards . it is stamped hi on one side, it goes toward 4 . MAINSHAFT, CLUTCH it is between 3and 4 . got 6 wings on it, beveled on one side to allow shifting , cut straight on other to engage gear . you should be able to check by takeing rachet cover off look and see if straight cut is on correct side karl check out site to see pics http://www.bikebandit.com/harley-dav...00-1971/o/m766

[Chop15]

Originally Posted by Jonas

I have a 1981 FLH. The transmission will pop out of third gear. I have orderd a Shop Manual for the bike and plan to pull the transmission soon.

Little History of the problem. (This was my brother's bike)

The problem started after he had the transmission rebuilt. He pulled it, took it back to the guy. After putting it back in the bike it did not take long before the problem started again. The problem got progresivly worse. The rebuilt transmission has less then 10K miles on it.

Any help or suggestions are appreciated.

I'v got an 81 FLH also , Same problem ....

[Hillside]

God only knows how many 4 spd. gearboxes are out there that need dire attention.
When we go through them we always use Andrews shift clutches,(better ramp angles) and forks.
9 out of 10 also need the MDG bushing re-fitted to the mainshaft.
Scott

[Jonas]

I pulled the transmission.

I checked the clutch. I can see engraving on the side towards forth gear. I believe that is in right.

It has Andrews Gears in it. They appear to be like new condition.

The edges of the dogs on the clutch for third gear, do show some wear.

I'm not sure if it's enough to cause the popping out of third problem or if it is a result of the popping out of third problem.

[Jonas]

I checked the shift forks. They were not setup correctly. The fork for 1st and 2nd were defenilty off(oddly enough there was no problem with first or second)

The 3rd and 4th fork was baised slightly towards third. The rebuilder probally shimmed it that way after my brother returned it for popping out of third. The damage was already done at that point.

I ordered a new third gear and the clutch. Looks like I will be tearing the transmission apart this weekend.

[Jonas]

I picked up the new gears today. I don't think the third that was in the bike was an Andrews Gear. The new Andrews Gear is different. See picture.

You cannot go by the letters stamped on the Andrews Clutch for the high side. The new clutch has the letters stamped on the opposite side.

Why are the gears different?

is the damage to the dogs enough to make it contantly pop out of third?

Thanks

[Jonas]

Springer gave me a little more in site to this problem. He has a gift for explaining things. He he can explain it to me then that is an accomplishment.

Another potential problem is the shifter plate. This plate positions the shifter forks into there proper positions. It is highly possible this plate is worn. You can almost see it in the picture. Compare the two points, one is worn and rounded.

He also gave me a few other things to look at and try.

Thanks Springer for the info.

[Jonas]

Got her all back together. Shifts great. Replacing the 3rd, the clutch/dog and adjusting shifter forks solved the problem. Many thanks to Springer for the phone support.

For your viewing pleasure

http://www.youtube.com/watch?v=oZIe0ebIYug