[JackM]

Oh, okay, no hard feelings. Looks like it was all a misunderstanding. I like helping people out in here, but on some forums I found that some people don't like that and want nothing more than to see me personally, and the shop, fail. I have been unable to understand why people do that. I am happy to be a paying vendor here and to help those out with tranny issues even if it means we won't get any business out of the time I spent posting. I jumped the gun there on you thinking you were another nut, sorry about that.

Well, I tore the unit back down and took another look at the teeth. They still looked great. I had a new hub and slider in there but replaced it a 2nd time just in case there was some issue with it and replaced reverse gear. The first time I kept the original Rev gear in there as it looked to be in great shape. Found it still had the problem.

When rebuilding it the first time, I found that the R gear shift fork was bent. I replaced it with a new one (as that is part of the rebuild he ordered anyway) but this issue was still there prompting me to do the above taking it apart the 2nd time. So I took it apart a 3rd time. I finally found that the shift rail was bent. The small fork at the end that attaches to the shift shaft assembly had a bend in it I almost couldn't see. I have never seen anything like this before and it seemed very odd. I replaced the shift rail assembly and now it stays in gear with no issues. It also feels like the rail slides a lot smoother now too. I filled the unit up with oil and ran it for a long time. I really beat on it good and ran the input shaft in both CW and counter-CW directions to really try to piss Rev gear off. Accelerating and decelerating and it never popped out once. It seems happy, finally.

I'm just happy he didn't get the unit and run into this problem having to remove it again and ship it back, because that just totally sucks. This tester I made has saved me on several builds and it's definitely worth the time to attach every unit I finish to it to just be sure. He has a 14 month unlimited mileage warranty on this thing, so we really need to make sure everything is perfect before he gets it. I shipped the unit out to him yesterday. Since this build took more time than usual, we offered to pay his $15 per day storage fees the shop was charging him as all of this annoyance with Rev gear wasn't his fault and could have been a lot worse if we didn't catch it.

Jack