Quote:
Originally Posted by Neil E.
The woodruf key is made of soft metal and is much softer than the gears. It is possible to have a small bit of the key wandering around without significantly damaging anything else. I would expect it to wind up on the magnet at some point. Based on the condition of your key I would guess that the crankshaft primary nut was not sufficiently torqued.
If a bit of key got stuck in the shift drum, it could prevent the pin on the first gear shift fork from travelling fully and this would prevent solid engagement of first gear. There is some uneven wear on your shift forks, but they don't seem too bad.
The gear dogs are on the sides of the gears. You need to remove snap rings and slide all the pieces off to really get a look at the mating surfaces. Do you know anyone with auto/truck gearbox experience? They could tell if anything looks suspicious.
With all of the shafts and gears assembled into one case half, you should be able to rotate them and watch the action of the shift drum, shift forks and gears. You need to verify that all related parts are moving their full distance when you engage first. The shift pawl also has to index the shift drum smoothly.
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Some good advice here... Are the transmission case bearings in good shape? Before you do your final reassemble, it would be a shame not to completely clean these bearings and not reintroduce and metal fragments or shavings.