I made a very expensive mistake! This winter I rebuilt my shifters and forgot to check the cable throw distance at the transmissions when I put the shifters back together. Long story short after only 10 hours on fresh rebuilds last season, in the matter of 30 seconds this season both BW 72c's overheated and one actually welded the clutches together (stuck in gear even if in neutral)

I am going to attempt a rebuild on my own as I am having trouble justifying spending another $14-1600 to rebuild them again.

I am pretty sure I am capable of performing this rebuild but wanted to see if there are any tips to tricks to these boxes? Anything I should look out for? I am going to attempt to simply replace the clutches as I know the rest of the boxes should be fine as they just got overhauled(assuming no metal from the clutches overheating)!

Any help you can give would be appreciated!

Thanks
Jim

Pls tell me before I make the same mistake.....

Did the actuator arm over/under engage causing less than positive engagement?

Under engaged. Once I figured out what was wrong and disconnected the cable from the transmission the linkage on the gearbox was about halfway between neutral and forward or reverse depending on the position of the shifter. It literally took 30 seconds at 3500 rpm's to burn them up! Still kills me to talk about it! STUPID..STUPID..STUPID

How much will be parts vs. labor? If mostly parts, this might not be worth being a DYI project.

About $400 in parts and $1000-$1200 in labor. This is why I am contemplating a DIY

There not too bad Jim, I have a bam super cyborg apart on the bench now. Mmb sent me a PDF of the Borg Warner manual, if you would like I can fwd it to you.

I actually also have a copy of the service manual! Found it somewhere on the Internet but thanks though!

I am going to give it a go, maybe if I run into a problem I will give you a ring! Thanks!!!

They are simple. All the literature is on the internet for a reason, everyone is handling it themselves