I'll try to make this short, but............

While on our recent 50 day cross-country, I developed a nice little leak out of the Shift Shaft Seal on our 2014 SGS. Had close to 95k on the bike at the time. Not a bad leak and it would wait till we got back. After we got back, I went in to replace the Seal, as well as install a new Dark Horse Man-o-War Motor Sprocket that I've been wanting. (see other thread I started on that). Anyhow, taking the suggestions of multiple people, I decided to use the smallest little wood screws I could find in my shop to remove the old leaky seal. Well, it apparently got crooked while screwing it in and left a nice not so little gouge in the sidewall of the bore in the Tranny Housing that the seal fits into. See pic below......






So what I've done to this point is, on the 1st attempt I lightly sanded the extruding burr off the damaged area, crossed my fingers and put a new seal in. Fail......
Next time I took a little dab of the Permatex Gasket Dressing (Hylomar Blue) that I had, right on the gouge, crossed fingers. Fail.....
Next time, after replacing the Shifter Mechanism Shaft that the seals ID rides on with a new one, (thinking it was worn/grooved/scratched), I took the same sealant, put some extra on the gouge and also lightly all around the the rest of the bore. Fail......
This last time I gooped the sealant all around the bore pretty good, but not too much, installed the seal, let it set up for a few hours, then reassebled everything and let it sit overnight. Better, but still fail.....
This is the sealant I've been using and I'm beginning to think maybe it's not the right stuff.......





So, I'm at the point where I can go back in and try it ONE LAST TIME before I either have to buy a whole new Tranny Case, ($600!), or take mine to the local Machine Shop and have my buddy do a "Bore and Sleeve" to repair what I phucked up. However......... I'm really thinking I can fix this with a different type sealant...... I think this stuff I've been using is too soft. What do you guys suggest as far as what sealant I can/should use to seal this? I REALLY don't want to pull the Tranny out for either repair or replace. There has to be a better sealant that I can use for this that will work, right? I have this other stuff, but I'm not too sure about that either. I'd rather hear from you guys first...........






On a side note, I'm getting really fast at tearing this thing down and putting it back together again, lol!! Plus, I found a great way to remove the seal without drills and screws. Just take the Tranny Cover off and push the Shifter Mechanism back into the Tranny and it gets the Shift Shaft out of the way so you can pop the seal right out! (see the top pic again) I love YouTube!!

 

I would think that a little of the red Permatex High Temp silicone gasket sealer should would fine on that. I use a little bit when installing most seals and gaskets.

One more thing that comes to mind is to make sure the transmission is vented correctly. Some times they can get clogged up building pressure in the case forcing oil out. Good Luck.

 

I put black around one I did once. Taking that top cover off one bike, had hard time cleaning old gasket off.

If you haven't with those miles I'd do belt and stator, plus primary bearings
I did sprockets and seals on main shaft too.

I am surprised rtv didn't take care of it.

 

I would try a two part metal epoxys. JB Weld springs to mind.

Then I saw this -

 

Tough one, not sure you could get the JB smooth enough in there to seat the seal. Maybe and just maybe, you could put JB in, oil up the outer bearing in that area and seat it in, once the JB has cured, pull out that seal and then use sealant? Just blabbing like others lol. Damn wood screws, hope you chucked it......

 

Wood screws are back in the wood screw drawer never to go anywhere another bike again! Yeah, I'm not feeling the JB Weld repair on this at all. I'm sure SOME sort of sealant will get it, just haven't decide on which one. Luckily, there are no bearings involved with this "screw" up, lol. Just the Shifter Shaft Seal. The Tranny vent tube and the hole in the gasket are clean as a whistle, so pressure is not in the equation. All things that can/should be updated while in this deep, have been, EXCEPT........... that damn backordered Shift Mechanism Shaft Sleeve!!! The Seal doesn't touch it, so that shouldn't be an issue........... I don't think.

 

There are no bearings. Seal it's in block,shaft goes through seal
I would not use jb cause won't be smooth. I wouldn't make hole any bigger.

I would have used black rtv around hole. I lost track of all the chemicals tried.

I hate leaks,but what point do you just brake clean until you change belt .

I rebuilt my tranny at 90 for hell of it, when putting in new belt.

 

So, upon pulling this last one out, the one with the little bit extra sealant, I noticed the sealant seems to have become sticky gooey, almost gummy, but definitely not set up like I would have thought and wanted to see. Did it have some sort of reaction with the Assembly Lube I used? The grease the the MoCo put on the seal? The Bel-Ray tranny fluid? I don't know, but it's too snotty for my liking.














With this in mind, I'm thinking clean the dog crap out of everything with brake cleaner and alcohol, leave the assembly lube, or tranny fluid, only on the ID of the seal and shaft, put a goodly amount of some regular high temp RTV in the bore, and instead of sinking the seal to the spec'd out depth of 0.120" - 0.140", I bury it up against the back of the bore. This will keep the seal lip still riding on the fresh surface of the new shaft. I've seen videos of guys setting the seal all the way back into the bore, and thinking it prolly won't hurt AND maybe help it to seal on a seperate surface. The sleeve is deep enough into the housing that it won't come in contact with the seal either. I'm really getting driven to fix this damn thing instead of pulling the whole tranny out for repair or replace, lol, but I'm starting to run low on options here.....

 

How did you measure the ID of the bushing?

Which direction did you install the seal?. Skirt spring needs to be on the inside.