Okay, so my ignorance is on full display here... The Heel/Toe shifter is very loose on my son's 1992 Fat Boy. You can still shift, but not easily and it's very sloppy. He came up with the 'return pull spring' is broken and I have no idea what that is. A local shop wants $1000 to fix it, saying you need to take the whole trans apart. So, is it going to be cheaper to find a new trans? Is this a job we want to take on ourselves? Is this an opportunity to upgrade to a six speed?

What are my options here?

 

The part you're describing is called the "shifter pawl spring", and it is a reasonably common point of failure.

Number 55 on this diagram:



There is even a "sticky" thread on this forum with instructions on changing it: https://www.hdforums.com/forum/evo-c...wl-spring.html

Take a look at that thread, then you'll be in a position to decide if you want to tackle this.

 

Seems like it would be easier to just replace the trans. Found one on Ebay for $250...

 

Not really. By the time you get the old trans out, you're 85% of the way to replacing the spring anyway.

 

Thats exactly right, if you are doing the wrenching fix the trans you have instead of rolling the dice.

 

I believe part 59 in diagram in the spring that fails.

 

And dont remove the main output gear in trans case, just pull the trapdoor and gear set and put a nice heavy spring on the pawl

 

Could be the lever loose on the shift shaft. But if the splines are bummed up on that shaft, still have to pull the gear set to replace it.

All but a couple of the special tools needed to change out the entire transmission are the same ones you'd need to simply repair what you have.

And pulling the entire transmission is a LOT more work than what's likely in front of you.

 

Good catch. You're right. 59 is the one known to break.

 

Before install the new spring, smooth out the sharp edge on part #58 where the pawl spring arm contacts that part. The sharp 90 degree edge is the cause of the spring arm breaking in the first place. Just slightly round off the sharp edges. You will see what I m talking about when you take things apart.