During a teardown, I found this piece of the shift fork shaft guide that broke away from the housing. The bearing housing opening that the shaft passes through looks great as does the clutch release.xover that the end of the shaft rests against and the shaft itself.
Can this be assembled and used safely with this guide not present? I mean the bearing housing holds the shaft in the correct position horizontally.
Being that the housing is aluminum alloy, is there any way to reattach this piece?
Photos of all components in question attached as is a photo of a transmission housing that is intact for reference.

Any thoughts or advice are greatly appreciated.

 

It's been a while since I had a 5 speed apart..
If you could post a pic of the shaft in position and measure how much the shaft extends from the trans case I could give a better recommendation..
Surprised the broken piece didn't jam any of the gears.. Any Idea how or when it happened? Why did you disassemble the trans?
Do you have the right side trap door guide pin? I don't see it..

 

So the trapdoor came loose? I'm not sure the fit for the shaft in the trapdoor is tight enough to leave the piece out.. If you want to get the case repaired, it will likely have to be removed. You might be better off getting an 01 to 06 used bagger tranny that's complete with low miles..

 

The bearing housing guide pin on the right side (forward side) remained in the bearing housing. I haven't pulled it and put it back in its spot in the trans housing. Attached are photos of the shaft inserted, view of amount of shaft is exposed beyond the side of the trans housing, as well as a measurement of the exposed portion .

 

since mine is already gutted, I found a couple of compatible housings online. Was just ruling out being able to reassemble and get away with free 99 for a budget

 

Definitely appears to be a lot metal on the gears, trans needs a good cleaning.. You very possibly will be able to have it welded properly and keep the proper alignment of the shaft but I would be more worried about what caused it to break in the first place.. Also do you know how long it's been like that and was there any issues with shifting? What made you pull the trans down?

 

Transmission teardown was for the purpose of replacing shift pawl assembly. I fear that when the bearing assembly guide stayed in the bearing housing on the right side, I could have possibly caused the fracture myself reassembling everything. The piece was.diacovwred after I had the trans probably 80% reassembled and fluid back in it. Had the shift forks incorrectly positives so had to remove side cover and bearing housing. Drained the fluid and removed the side covers and the piece that broke off of the guide was in my drain pan. It did not break off during operation and bounce around inside during operation.
Either way, the transmission cannot continue with the missing piece not welded back in correct? My original question was whether the opening in the bearing housing that the shift shaft feeds through could support the full load of the gear shifts without having the guide hole intact.
I know that simply replacing the housing makes more sense. I was just curious if it was 100% necessary.
Thanks again.

 

It might work if the fit on the shaft in the trapdoor is the same clearance as the busted hole. IIRC it's kind of loose. Heck you might be able to machine a spacer to tighten it up but at that point might as well replace the case..

 

I appreciate that idea. I know a housing swap is the sensible, safe route. Was wondering if it would be avoidable and just wanted to bounce some ideas off some more experiences wrenches. Thanks again for your help

 

This is what I was thinking, I would assemble and see just how much play there is in the fit of the shaft to the trap door and go from there.. I don't think it would make that much of a difference and personally I would at least try it before replacing the case.. I don't think it would create issues with the sift forks but might increase the distance between the shift fork and shift drum but even that will be minimal..
Keep in mind, I don't think I've ever seen or heard of this issue before.. It's a first that I know of.. I would still try to assemble to see if there would be any binding issues..