[Bankerdanny]

Attached is a pic of the detent plunger from my 4-speed.

It's hard to tell from the diagram in my manual, but based on the description, this seems wrong. I think that part has been sheered off.

Vince or anybody else with some 4-speed experience, am I guessing right, do I need a new plunger?

[t120rbullet]

I would venture to say that yours needs repair.

[Bankerdanny]

That's the same conclusion I came to. I don't know how it got so damaged.

[t120rbullet]

Unless it was screwed in way too far I can't thing of anything in there that would do that.
How does the gear operator look? I would imagine that it's pretty messed up too.

[Bankerdanny]

Clearly I have to open the transmission AGAIN. 

[t120rbullet]

You can see it through the hole the plunger came out of.
Might save you tearing into it any further.

[Bankerdanny]

It might still be in place. We'll see.

At this point I have become quite adept at removing and reinstalling the transmission covers.

[Vince]

     Talk to Kevin at CMW. He used to have an improved plunger to help shifting.

[t120rbullet]

Here is a tidbit from the Danish importer Jan O. Nielsen off the E-Group (Yahoo group) of yesteryear,

"BE GOOD TO YOUR GOSA ... and your GOSA will be good to you!

Take off the gearbox cover. Inside in the upper right hand corner you'll find a
screw with a lock nut on it. This screw is the GEAR OPERATOR SELECTOR ASSY (part
no.111094), the "GOSA".
Take out the GOSA. The pointed end of the GOSA is held by a spring, and this is
the arrangement that together with the GEAR OPERATOR INSIDE (part no. 111083)
keeps the gear wheels in position.
The problem with the GOSA - according to our mechanics - is that the spring
inside it too often too hard and that the pointed end is too rough. You can
polish the end of the GOSA so that it becomes very smooth, but remember that it
has to remain pointed.
With a little screwdriver you can detach the pointed end of the GOSA and remove
the spring. Replace the spring with a spring only half as hard and attach the
pointed end again.
(You can also - like one of our mechanic do - simply drill the inside of the
GOSA deeper, thereby relieving the tension of the spring. But there is no going
back from this)
The pointed end of the GOSA should now be easily moved up and down.
Screw the GOSA back in again all the way and then turn it back again two or
three clicks.
The slot in the GOSA should be horizontal when in place and then you can
retighten the lock nut while holding the screw horizontal.

Now you gear should be easier to operate, but remember: no guarantees!

Please let me know if I'm unclear. My technical english could be better."


The factory started using weaker springs shortly after this came out but still can be improved on with honing and polishing,
CJ

[Bankerdanny]

I just ordered a replacement from CMW. I am keeping my fingers crossed for nice weather for the 3 day weekend upcoming so that maybe, just maybe, I can get this work done and actually ride.

However it goes, this is my last weekend trying to do this myself. If I can't get it done then off to the dealer it will go. I am tired of working out it, I want to ride and in Chicago the riding season is not long enough that I can waste another 2 months trying to fix it on my own.

[geoffbaker]

I just ordered a replacement from CMW. I am keeping my fingers crossed for nice weather for the 3 day weekend upcoming so that maybe, just maybe, I can get this work done and actually ride.

However it goes, this is my last weekend trying to do this myself. If I can't get it done then off to the dealer it will go. I am tired of working out it, I want to ride and in Chicago the riding season is not long enough that I can waste another 2 months trying to fix it on my own.

Good luck with the new part. That GOSA sure looked beat!

If it's any consolation.. your gearbox troubles have been of great use... I have learned a lot from them and have saved and even printed out some of the descriptions, to aid in my LH to RH shift conversion, which is still awaiting testing, when I get my diesel in. Your problems, frusttrating as they were for you, helped me prepare for a scary ordeal... opening up and working on my transmission!

[Bankerdanny]

Happy to be of service.

[Bankerdanny]

Got my new detent plunger today, I didn't realize how badly damaged mine was.

The thing is I just can't remember the condition of the plunger when I first opened up the transmission in April.

I don't think that it was damaged then. I suspect I overtightened it during reassembly. I didn't know that the tip is spring loaded.

Hopefully I didn't chip a gear or do some major damage.

[t120rbullet]

Might be a good idea to flush the box out with ATF a few times just to get the chunks out if there are any.