Worn Shift Rails? [Pics]

[360glitch]

After finishing up dis-assembly, the only obvious damage that I've found so far appears to be to my shift rails. I have never seen any other shift rails, so this may be normal, however, I would think not:

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While I am at it, here is some more wear, on the actual housing:

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Back to the rails, I have poked around a bit online and have not had any luck finding any info on this. Anyone else have any experience with this sort of thing?

 

[twicks69]

The rail end on the 3/4 shift rail looks a bit beat up, but usable. As for the other rail ends, they are usable.

The wear on the case from the lower intermediate tapered roller bearing being out of spec won't matter. Just replace the lower and upper tapered roller bearings on the intermediate shaft and reshim, and you will be set to go.

If you are reusing your first gear, properly debur and detail the gear so that any sharp edges or worn edges are cleaned up with a 1/4" diameter x1/2" long 120-grit sanding drum and a dremel.

The replacement parts you would want are listed below:
1st Gear (DSM 3.083 Gear Ratio) MD743179
Intermediate Shaft Inner Bearing (ALL YEARS) MD726236
Intermediate Shaft Outer Bearing (ALL YEARS) MD736638
3/4 shift rail (late 91-early 92 - for shift fork with 2 hiles on 3/4 shift fork) - MD739795
3/4 shift rail (late 92-94 - for shift fork with 3 holes on 3/4 shift fork -- 2G style shift fork) - MD741155

 

[360glitch]

The rail end on the 3/4 shift rail looks a bit beat up, but usable. As for the other rail ends, they are usable.

The wear on the case from the lower intermediate tapered roller bearing being out of spec won't matter. Just replace the lower and upper tapered roller bearings on the intermediate shaft and reshim, and you will be set to go.

If you are reusing your first gear, properly debur and detail the gear so that any sharp edges or worn edges are cleaned up with a 1/4" diameter x1/2" long 120-grit sanding drum and a dremel.

The replacement parts you would want are listed below:
1st Gear (DSM 3.083 Gear Ratio) MD743179
Intermediate Shaft Inner Bearing (ALL YEARS) MD726236
Intermediate Shaft Outer Bearing (ALL YEARS) MD736638
3/4 shift rail (late 91-early 92 - for shift fork with 2 hiles on 3/4 shift fork) - MD739795
3/4 shift rail (late 92-94 - for shift fork with 3 holes on 3/4 shift fork -- 2G style shift fork) - MD741155

Thanks for all of the info. Anything in particular that could cause this much wear on the rail ends?

 

[twicks69]

Thanks for all of the info. Anything in particular that could cause this much wear on the rail ends?

Hard shifting, low viscosity gear oil, mis-shifting, etc.

If you have any other questions, feel free to contact me!