Jerico DR 4 disassembly

[John67427]

My first time working on the internals of a Jerico DR4. It’s a top/ bottom loader case. I need to replace the input shaft to match my clutch discs. The trans is new even though it’s an older version. I have the top cover off and the outside snap ring removed. I can get the front bearing to start but don’t want to screw anything up. Just trying to not take it apart more than I have to. Any advice would be appreciated.

[cjshaker]

While I've not had my DR4-4 apart yet, I'm going to make an assumption here:

The Jerico is basically a Toploader in design. In a Toploader, the input shaft will hit the countershaft gears when trying to remove it. You can get around this by taking a wooden dowel, or something equally appropriate, that is smaller than the countershafts shaft, and sliding it into the countershaft, while pushing the original shaft out. This allows the cluster gear to drop slightly, which allows the input shaft to clear the gears and be removed out of the front of the case. A little care must be taken to keep the roller pins in place inside the cluster gear.

I would assume this would work for the Jerico as it does on a Toploader.
If it doesn't, remember that this advice was free. 

[John67427]

Thanks Doug,
  I was looking at it again this morning and I think your suggestion is a possibility. Thanks You!

[Stangman]

Funny you responded Doug I was going to post yesterday that I thought you might know.

[6667fan]

John, I have done that job on my DR4-4. I don’t recall having to mess with cluster shaft. I think you are on the right path. The key is being able to remove that giant clip on the outside and the smaller E clip inside. The bearing is an interference fit and will take some patience tapping around its perimeter and perhaps waving a propane torch over the case. I will look for pics I took.
Bob Treadway talked me through it. He builds boxes for the SEGA guys.

[John67427]

Thanks Jim,
  Missed seeing you at the FE Reunion. Hope all is well!!!

[fekbmax]

Just curious as to why you rather go through the trouble and change the input shaft on a new transmission rather than changing the disk. My assumption is you must have a good supply of disk already.

[John67427]

It’s a spare Keith. If something goes bad I just want to take the broken unit out and stab the good one in. I‘ve been hammering gears on this Jerico for over 27 years and never missed a gear. Unfortunately I’m afraid one of these days my luck is going to run out

[fekbmax]

I hear ya, I have a spare CL 4 with a long shifter installed under the bench, got it in 2011 and it's only seen jack stand time. She's  been ready to go if ever called on though. . Need to get rid of it but not much market for the older Jerico's .