Alpha one Gen 1 shift shaft screws stripped

rmoreaux1

Cadet
Joined
Jun 28, 2013
Messages
6
Hi guys, I have a 1987 Alpha one drive and have replaced the gimbal bearing and bellows but couldn't get the upper shift shaft out of the bellhousing because it was stripped. I am going to try and salvage the shaft if I can but cannot find out which screw comes out first. Does the long set screw on the side come out first or the the top screw. I made a pretty neat bellows tool to go around the shift shaft since I couldn't remove it and it worked great. I will probably post a photo of the tool. I removed the drive after a few uses to check for any water and found that the shift shaft seal is leaking and it needs removed to put a new one in.

I saw there is an upgraded shift shaft seal and that is the one to buy is there anything else that needs to be done in order to use the upgrade such as enlarging the shaft hole size?

Also, has anyone else had a problem similar to the shift shaft screws being stripped out. They were a a little messed up before I tried to remove them but both screws are stuck so I cannot tell which one to remove first.

I would just cut the old one out and replace with new but I recently had surgery and funds are on an as needed basis and I have plenty of time to fiddle with the old one to save some cash and hopefully save me from going crazy sitting in the house. If I have no other choice than to cut it out so be it but I think there should be a way to reuse this one.

Thanks for all the help. I have read a lot of the threads around here and found all the info I needed except for this particular issue. Everyone just says remove the shift shaft. So, my stuck screws must be rare. I could not find the manual for download in the adults section.

I made all my own tools since I have plenty of time to rig up a simple tool. None of them are the greatest looking as they simply were made to function, but they all worked great and I have no problem using them again. I did buy an alignment tool.
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: Alpha one Gen 1 shift shaft screws stripped

That screw is loctited in, so it is usually VERY tight. The most common method of removal its to strike the arm with a hammer and drift and it breaks across the screw hole. Then just pull the screw out and drop the upper shift shaft down. All you need is a new lever... Part # is -45518A3... and screw (# 10-45590) if that's damaged, but it's usually just the arm...

Chris.........
 

bspeth

Senior Chief Petty Officer
Joined
Aug 30, 2013
Messages
762
Re: Alpha one Gen 1 shift shaft screws stripped

The manual says to apply heat if necessary,you could try that first.I don't think there is one on the top,just looks like there is.
 
Last edited:

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: Alpha one Gen 1 shift shaft screws stripped

The manual says to apply heat if necessary,you could try that first.

If the screw is stripped, that will not help. Also, aware that when using heat, there is a plastic washer under that level. It usually ends up dead at the end of the job...

Chris....
 

bspeth

Senior Chief Petty Officer
Joined
Aug 30, 2013
Messages
762
Re: Alpha one Gen 1 shift shaft screws stripped

:facepalm:my bad.Thanks for the tip on splitting the lever though.
 
Top