Author Topic: Ca95 tranny repair (Read 7338 times)

Sdsbassist · « **on:** January 13, 2018, 08:18:18 pm »

Any of you guys ever split the top and bottom part of a baby dream case to replace or repair the transmission.

My big concern is how to get the bottom end off. It seems stuck. I've taken off clutch, stator, oil pump etc and all bottom case bolts.

I know there is a fair amount of gasket maker on the case.....

Do I use a screwdriver to try to get it started? Sharp knife? Any help appreciated!!!

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Sdsbassist · « **Reply #1 on:** January 13, 2018, 08:18:59 pm »

Pic for fun.

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jgger · « **Reply #2 on:** January 14, 2018, 09:29:12 am »

If it is like the class and cb motors I think there is 1 bolt from the opposite side of the other bolts. If all the bolt heads are on top, flip it over and look on three bottom. The motor should be upside down when you do split through cases.

Sdsbassist · « **Reply #3 on:** January 14, 2018, 09:34:36 am »

Could be....haven't taken any blt off top part. I'll give it a look today.

Thanks!!!

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Sdsbassist · « **Reply #4 on:** January 14, 2018, 10:36:04 am »

Jigger. That was the ticket! Off she came.

Here were my symptoms:

In first gear it would pop in and out all the time. I adjusted clutch ect and made sure all was well there.

Why should I be looking for? Shift dog issues? Chips in gears? Shaft issues?

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jgger · « **Reply #5 on:** January 14, 2018, 10:59:52 am »

Mic the shift fork and the groove it runs in, in the gear, I don't know what the spec should be but if you check both of them (1st/2nd & 3rd/4th) you can see if one is really worn out. Also look for wear in the side of the fork that pushes it into 1st gear. A worn or bent shift fork will cause your issues.

Where the fork is attached to the shift drum (IIRC) there is a bolt and a bushing that rides in the groove in the drum, check there for wear also.

Then the most obvious would be to look at the dogs on 1st gear to see if the are chipped or rounded off, that can cause them to pop out of gear too.

This all based on my experience with my CL72 (250 Scrambler) from many-many moons ago. I hope it points you in the right direction. BTW that CA95 is a 305 motor, right?

Sdsbassist · « **Reply #6 on:** January 14, 2018, 11:06:34 am »

No its a 150. I got a 305 up next

Mind if a snap a few pics for a second set of eyes? I sincerely appreciate your help!

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jgger · « **Reply #7 on:** January 14, 2018, 11:08:43 am »

Go for it! But I have to warn you my eyes are old, but at least my memory is short to make up for it!

Sdsbassist · « **Reply #8 on:** January 14, 2018, 11:15:01 am »

I don't see anything obvious other than wear on the dogs.

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Sdsbassist · « **Reply #9 on:** January 14, 2018, 11:15:16 am »

Check that, not dogs, forks

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jgger · « **Reply #10 on:** January 14, 2018, 12:00:09 pm »

Did you shift it through the gears with the cases open? I'm not sure but I think that what the 2nd and 3rd pics show is 2nd gear engaged (I could be wrong). If that is the case then your engagement is for the "slider" gear to be moved to the left and engage in the oval holes. If you look at the leading edges of the first two gears on the left (the dogs) they both look rounded a bit. This could be the issue. Can the gear all the way on the left be flipped around to get a sharper edge to hold the engagement?

This is all speculation though. I noticed in your very first pic of the tranny open that the bearings do not have a snap ring on them and the cases look like they have a groove for the snap ring. This might have some impact on how the fixed gears align in relation to the shift fork/slider gears mate. In the picture it looks like the grooves do not align between the case and the bearing, could be just the angle of the camera though.

Did you measure the shift forks? Or check for slop in the mechanism?

Sdsbassist · « **Reply #11 on:** January 14, 2018, 01:49:54 pm »

I don't see the top snap rings either. I'll look at the case and see if there are grooves for the bottom. There are groves and snap rings in the top half.

I can measure the shift forks soon. I'd say there is some slop in the low gear.

Thanks again. Here's a video.

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754 · « **Reply #12 on:** January 14, 2018, 05:48:40 pm »

Shift fork on right looks melted toward top, need a side shot of it,
And the one dog shown looks pretty rounded.

jgger · « **Reply #13 on:** January 14, 2018, 06:25:09 pm »

After watching the video it looks like that gear that you are wobbling around looks shot, it should not have that kind of movement. There should be a bronze bushing where it rides on the shaft, that looks to be worn out. I hope it didn't wear into the shaft.

Sdsbassist · « **Reply #14 on:** January 14, 2018, 06:41:25 pm »

More pics as requested. I'm becoming more convinced the gear is wobbling or shifting in and out of place.

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Sdsbassist · « **Reply #15 on:** January 14, 2018, 06:48:34 pm »

They are out there....

23420-205-010

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F272931368883

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jgger · « **Reply #16 on:** January 14, 2018, 07:00:27 pm »

That looks like a good price, might want to jump on that one.

Sdsbassist · « **Reply #17 on:** January 14, 2018, 07:05:20 pm »

If I could definitively tell it was better than the one I have I probably would.

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754 · « **Reply #18 on:** January 14, 2018, 08:30:53 pm »

Now I cant see the shift fork, just feel inside it for the burr I can see in the pic, then compare the gear and dogs to the others, or the opposite sides of the hole/dog.... Not hard to see.

jgger · « **Reply #19 on:** January 14, 2018, 08:42:54 pm »

Frank did you look at the video he posted? Then look at the pic of the single gear above. The bushing looks like sn egg and the holes where the dogs engage are rounded pretty bad.

The fork might be bad, but the gear is worse. Watch the vedio and check out how much wobble is in there.

754 · « **Reply #20 on:** January 14, 2018, 10:13:16 pm »

Whoa that s a lot of play, bushing will cost half the price of the tranny, and you may still not have 1st gear .
Plus there could be a shim or spacer missing which caused it in first place... The less the gear engages, the easier it slips out.

Sdsbassist · « **Reply #21 on:** January 16, 2018, 03:10:37 pm »

I bought it. On its way!!!

Would kind of bond do you use to seal the cases again?

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jgger · « **Reply #22 on:** January 16, 2018, 04:19:37 pm »

Not sure what you want to seal it with. Just wanted to say don't just drop the whole thing into your cases. Mix and match all the best parts from both trannies. Don't forget to check the bushings and bolts on the shift drum/forks.

You should be able to put together a real nice trans, good luck!

Sdsbassist · « **Reply #23 on:** January 16, 2018, 04:22:44 pm »

I put on about 200 miles a year on the girl. Hoping this will last until one if the kids gets her.

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Sdsbassist · « **Reply #24 on:** January 22, 2018, 05:47:11 pm »

So picked all the best parts and built up tansmission. Here's the only issue:

When I try to manually shift through the gear I get binding sometimes, especially on third gear. Now there isn't much oil, and I'm just spinning in by hand. If I turn the counter shaft or main shaft just a bit it usually will then engage.

Am I being paranoid? My dad was over and he looked and didn't seem to terribly concerned. He like i, thought that when the motor is actually running and spinning at 1000rpms those gears should engage no problem.

Any thoughts from you gents?

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Author Topic: Ca95 tranny repair (Read 7338 times)