Pulled my transmission cassette because I am trying to do the Baker Cruise Drive Refresh bundle (if it ever gets here). This adventure started into it on the shifter pawl having too much lateral play, damaging seals, and causing a leak. While I had it apart I figured why not give it what it needs to be good for a while... and the plot thickens. I noticed that the countershaft 5th gear has the pulley side chamfered. Also the Mainshaft 5th gear has a groove cut in it. The rest of them look ok and I haven;t completely diassembled it yet to more carefully inspect the rest.

Questions: Are either of these supposed to look like this (mainly asking about the countershaft)? If not, what is the cause? Confirm they must be replaced? What else to look for, specifically? Any feed back is greatly appreciated.

07' SG w/ 60k miles, stock 96" until last year, then: Darkhorse Bottom, Fuel Moto 110" Top with the appropriate accompanying upgrades..It Pulls.

 

Update (FYI I guess since this got plenty of reads and no responses):
>The countershaft gear is supposed to have the chamfer. The groove on the mainshaft 5th gear is no bueno.
>4th gears are well aligned, so using that as a datum the gap on the mainshaft from 4th to 5th gears is .045" while the gap on the Mainshaft is 0.086. Leaving an overall difference of 0.041";it's not a lot, but it is about how far into the mainshaft gear the groove is.
>I suspect that the needle bearing beneath the mainshaft 5th gear is to blame and it wobbling caused the groove.
>That doesn't explain why these 2 particular gears aren't aligned
>Now wondering if there isn't a way the shim out the gear the get them lined up or if that's even worth the effort if the needle bearing is the culprit.

Still open to feedback if anyone has experience on this one.
Thanks Again!

 

Dude. Most of the guys on here me included haven't been that far into a 6 speed. I would shoot Mark at Baker a message and make an inquiry with him. He's usually pretty good about advice in these instances. Im curious as I have an 07 with 50000 miles on it. I wish I was more help.
Good Luck

 

Last one I opened up was a "98 RK . Every needle bearing set was shot.

 

 

I agree the tooth damage on 5th gear is not good. As for your other points all I can suggest is you consult your FSM and take into account NELS' comments. You are already far enough into this to continue stripping and hence complete a proper rebuild!

 

The whole thing is torn down now. All the needle bearings (including the one on 5th gear seem to be ok. Since its apart I'll swap them for new regardless, but I still haven't found a satisfying answer to the issue.
I have found that HD changed 5th gear to a helical in 09' citing noise as the reason but I can't help but wonder if they also knew about this issue and the newer design addressed it.
That leads me to wonder if I could swap an 09 (or newer) counter shaft and fifth gear (main shaft) with the rest of my existing stuff and the new bearings and be sturdy again?
I also wonder if there is anyone out there with access to the MoCo bulletins that could see if this was ever something they addressed.