Hello all. Brand new to the forum and to Harley's. I've aquired a '98 FLHTCU-I 95th aniversary edition. The trans shift rod is loose. I've read several posts and I see this is not uncommon. I have the opposite problem of the previous post. It would appear the fix is easy enough but there isn't enough room between the end of the shaft and the primary case to remover the lever. I've removed and cleaned the pinch bolt but the splines on the cast-metal lever are worn. I've ordered a new steel version. Does anyone have any ideas or do I need to move the trans/primary case to gain enough clearance to remove the lever?

PS: the splines on the trans shaft look good.

 

The primary covers must be removed.

 

Thanks Dan. I'm wondering if there's enough room in there to use a Dremel and cut-off wheel to cut through the lever (opposite the pinch bolt) to separate it from the shaft. The steel version is narrower and looks like it will fit between the shaft and primary case. I might give that a try this weekend. The primary case looks like a lot of work to remove. Do you think removing the shaft through the transmission case is any easier if the dremel idea doesn't work ? The manual says it can be done while in the bike.

 

Here's a really good video from Baker detailing the DD6 install. Beginning around 3:46 they touch on the shift pawl/shaft. It might give you an idea of what needs to be done. Totally agree that the inner primary needs to be removed.