Question about 2002 Harley Davidson FLHTCUI Electra Glide Ultra Classic

1 Answer

02 flhtci remove entire transmission with gear cluster still in case

The manual states to remove gears and slide back with out gears installed can it be done any other way?

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  • Harley Davidson Master
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Hi Mike, to do any type of transmission work, the transmission case/housing stays in the frame. The bearing housing, main and countershafts with gears come out as an assembly. Good luck

Posted on May 01, 2015

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Posted on Jan 02, 2017

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wd4ity
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SOURCE: '02 FLHTCI - fuel gauge erratic- keeps pegging on

Sounds like a loose connection to me. On my FXDWG, the gauge has a rubber ring around it that holds it into the fuel tank. Carefully rock the gauge side to side while gently pulling up on it. Do not twist the gauge and be careful not to pull upwards too hard. The wires under the gauge are relatively short. The gauge will be in your hand and the sending unit is in the tank, Check all wires for a good connection.

I don't know of a test for the gauge. We used to test gauges in automobiles by taking the sending unit wire loose and then grounding it. When the wire is loose, the gauge will read full scale in one direction, when the wire is grounded, the gauge will read full scale in the other direction. Testing the sending unit is more difficult as it's basically a rheostat or variable resistor. You would have to remove the unit from the tank. The sending unit has a float on the end of a long crooked rod. It can be a real treat trying to get the sending unit out of the tank without bending the rod. If you bend the rod, the gauge will not read correctly even if everything else is right.

I'd check the wiring connections first. For what it's worth, these gauges are not known for their reliablity and quite often fail. Since your bike is fuel injected, you really need though. Mine doesn't work anymore and I use my trip meter to tell when I need fuel. Between 150 & 200 miles, I look for a gas station.

Posted on Oct 22, 2009

bdrew1340
  • 448 Answers

SOURCE: harley 2012 FLHTK replacement transmission

You can buy the entire transmission as an assembly, just the gearset, or any individual parts.

Posted on Aug 07, 2012

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How to install a speedometer cable on a 1956 bel air


The cable housing screws off of the transmission tailpiece and the speedometer head at the back of the instrument cluster. Once you have both end loose pull the old cable from the end you removed from speedometer cluster. be sure not to leave part of the old cable in the transmission. Cable should be squared off on both ends. Screw the housing onto the transmission finger tight. Rub lithium grease on the entire length of cable being careful not to get too much on it. Feed the new cable into the housing from the instrument cluster end, twisting the cable so the squared end will slip into the speedometer gear at the trans. once it slips into place you will not be able to twist it. Then insert the cable into the speedo housing at back of instrument cluster, finger tightening the nut onto the threads. That should do it. Additionally, you may want to inspect the cable housing for wear or kinks and replace if needed. Hope I've helped.

May 31, 2014 | Chevrolet Cars & Trucks

1 Answer

Shaft removal


The differential cover has to be removed to drain the oil from the differential. The cluster gear pin has to be taken out to get to the C-clips that hold the axles in. Try to position the carrier assembly so the retaining bolt to the cluster gear pin is on the top near the back of the differential. Remove the retaining bolt and the pin should slide right out. Take care not to rotate the the ring gear because the cluster gears will fall out and they are a little hard to get back in. Reverse this procedure to put it all back together. I hope this is helpful. Good luck.

Mar 26, 2014 | 2007 Ford Ranger FX4 Off-Road

1 Answer

I have a 2001 chevy tracker Manual transmisson The only gear it will move in is 4th When u try any other gear it acts like its in neutral Any ideas


The manual transmission uses a mainshaft that is locked in 4th and gives the 1:1 ratio. The rest of the gears come off the input shaft of transmission to a counter gear cluster then back up to output shaft. Either the input shaft gear or the gear on the counter shaft is stripped. That would cause the only fourth gear drive.

Feb 16, 2014 | Cars & Trucks

2 Answers

4wd first gear ok but problem with changing to second and third . My reverse gear works .


"Generally" in manual transmissions, first and reverse gear are on the same gear cluster, thus if one works both do.
However, the remaining gears are on what 'used' to be referred to as the 'cluster gear' and this 'cluster' could fail, still leaving you with first and reverse gears.
Hope this helps.

Oct 31, 2012 | Cars & Trucks

1 Answer

Plymouth grand voyager 1999 is not showing the readings on my dash for the fuel, speedometer, and has not passed emissions. What could be the problem?


Here is the procedure to check the gage connector on the back of the instrument cluster. The procedure is a lot longer if you have a mechanical PRNDL indicator in the cluster. I'm thinking you don't. You don't need to remove the cluster as the procedure says, because you're just going to check the connectors on the back. You just need to take the screws out and tilt it forward far enough to reach in and push the connectors in.


REMOVAL & INSTALLATION See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12

jturcotte_376.jpg

Fig. Fig. 1: To access the instrument cluster mounting screws, remove the lower bezel ...


jturcotte_377.jpg


Fig. Fig. 2: ... and the driver's side end cap ...



jturcotte_378.jpg


Fig. Fig. 3: ... to access the upper trim bezel screws. After removing all of the screws ...


jturcotte_379.jpg


Fig. Fig. 4: ... carefully pull the upper bezel from the instrument panel

  1. Disconnect the negative battery cable.
CAUTION The models covered by this guide are equipped with a Supplemental Restraint System (SRS), which utilizes a driver and passenger side air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described earlier in this section.

jturcotte_381.jpg


Fig. Fig. 5: Once the bezel is removed, the instrument cluster mounting screws can be removed (two on each side)

  1. Disable the air bag system.
  2. If equipped with a mechanical transmission range indicator, perform the following;
    1. Remove the lower steering column cover.
    2. Remove the knee blocker reinforcement panel from under the steering column.
Remove the indicator cable loop.
    1. Remove the clip securing the gear shift cable end to the gear selector adapter.
    2. Pull the cable end from the gear selector.

  1. Remove the instrument cluster bezel.
  2. Remove the mounting screws securing the instrument cluster to the instrument panel.
  3. Rotate the top of the cluster outward.
  4. Disengage the wiring harness connectors from behind the cluster assembly.
  5. Remove the instrument cluster from the vehicle. If equipped with a mechanical transmission range indicator, carefully guide the range indicator cable and guide tube through the opening to avoid any possible damage.

jturcotte_382.jpg


Fig. Fig. 6: After the mounting serews are removed, reach behind the cluster and unplug the electrical connectors ...





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Fig. Fig. 8: Instrument cluster mounting detail (models with a mechanical transmission range indicator)



jturcotte_1401.gif

Fig. Fig. 9: Range indicator cable mounting detail
To install:

  1. If equipped with a mechanical transmission range indicator, verify the free travel of the range indicator cable from P to 1 by gently pulling on the cable, then relaxing the cable. Do NOT snap the cable once it is pulled.
  2. Position the instrument cluster assembly into the instrument panel by leading the bottom of the cluster in first, plug in the wiring harness connector(s), and rotate upward. If equipped with a mechanical transmission range indicator, route the indicator cable and guide tube through the opening in the instrument panel.


jturcotte_383.jpg

Fig. Fig. 10: On models with a mechanical transmission range indicator, the cable must be accessed by removing the lower steering column cover. Remove the mounting fasteners, and lower the cover ...


jturcotte_385.jpg


Fig. Fig. 11: ... disconnect the parking brake cable ...


jturcotte_386.jpg


Fig. Fig. 12: and remove the reinforcement

  1. Install and tighten the instrument cluster mounting screws.
  2. Install the instrument cluster bezel.
  3. If equipped with a mechanical transmission range indicator, install the indicator cable and guide tube. Install the cable retaining clips.
  4. Install the knee blocker reinforcement panel.
  5. Install the lower steering column cover.
  6. Connect the negative battery cable.

Apr 01, 2011 | Plymouth Voyager Cars & Trucks

2 Answers

My speedometer is not working is it a cable? a fuse? a relay? i need to fix 1985 buick lesabre 307 v8 4 barrel rocker


Yes it is the cable type. The instrument cluster must first be removed. Depress the retaining clip on the back of the cluster to release the speedometer cable. Once the end of the speedometer drive cable is exposed, grip the inner cable with pliers and draw it out of the housing. Installation is the reverse of removal, but lubricate the entire cable. Use special speedometer cable lubricant, Not oil, for this purpose. Insert the cable into the housing using a twisting movement until the lower end is felt to engage with the pinion gear at the transmission. You can also check the Pinion Gear at the transmission, That is where the speedometer cable connects to the transmission. Some times these small nylon gears will strip out caused from no lubrication in the speedometer cable housing. If the above does not solve your problem you may need to change out the cluster itself to obtain a good working speedometer head. Good Luck and Happy New Year. From Ernie @ RedDeer, Alberta, Canada.

Dec 30, 2010 | 1985 Buick LeSabre

1 Answer

How to take out the input shaft on a 1995 gmc


I'm assuming that you are working on a manual transmission. The first thing required is thoroughly clean the outside so that no grit is introduced into the gears and case. The 'cluster' gear assembly must have it's bearing shaft removed so that it will drop into the case enough to allow the input drive gear to pass out of the front hole. Unless you install a special short shaft into the cluster gear as you remove the regular shaft, the small needle bearings inside the cluster gear will fall out of place and the entire gear will need to be extracted, coat the needles with grease and pack the needles back in place (hoping that you didn't lose any!). Be sure to inspect all bearings and gears for excess wear or damage. Good luck!

Jan 17, 2010 | 1995 GMC Sonoma

1 Answer

Have a 2002 chevy silverado truck.4.8L wont shift into reverse .Someone told us it was possibly the sun gear. need diagram wher this gear is located.


it is necc to remove transmission and dissasemble
entire transmission it is the first piece installed in the case i recomend visiting your local trans shops sorry

Nov 12, 2009 | 2002 Chevrolet Silverado

2 Answers

1995 Cougar Odometer/trip-meter inop


Section 13-01: Instrument Cluster—Conventional 1995 Thunderbird, Cougar Workshop Manual REMOVAL AND INSTALLATION Instrument Cluster Removal and Installation
  1. Disconnect battery ground cable (14301) .
  1. Remove screws holding instrument panel reinforcement (017A28) .
  1. Remove screws holding instrument panel lower shield (045G02) .
  1. Remove fasteners holding steering wheel column as outlined in Section 11-04 . Gently lower steering column.
  1. Remove fasteners holding the instrument panel finish panel (044D70) and gently pry off.



  1. Remove four instrument cluster retaining screws. (Do not remove screws from the instrument cluster main lens (10887) and instrument cluster mask (10890) ).
  1. Slide the instrument cluster (10849) to the right of the instrument panel opening and unhook the instrument panel harness from the back of the instrument cluster .
  1. Remove the instrument cluster from the instrument panel (04320) .
-----------------------
Speedometer/Odometer Federal law requires that the odometer in any replacement speedometer (17255) must register the same mileage as that registered in the removed speedometer . Since the speedometer mileage cannot be reset on this unit, affix odometer sticker to driver's door pillar and record original vehicle mileage. Removal
  1. Disconnect battery ground cable (14301) .
  1. Remove the instrument cluster (10849) as outlined.
  1. Remove seven screws retaining the instrument cluster mask (10890) and instrument cluster main lens (10887) .
  1. Remove speedometer assembly.
Installation
  1. Position the speedometer assembly to the instrument cluster back plate (10848) and install.
  1. Position the instrument cluster mask and instrument cluster main lens to the instrument cluster back plate and install the seven retaining screws.
  1. Install the instrument cluster as outlined.
  1. Connect battery ground cable and check the operation of the speedometer .
please rate if this helps

Mar 24, 2009 | 1994 Mercury Cougar

1 Answer

1987 Volkswagen Golf - speedometer problem


Well I would verify the trany speed gear is "ate up" first, theres only one 10mm bolt that holds it in place, sure the area around the speedo cable is very CLEAN before removing it any dirt in there would make things bad to say the least. If you pull the cable out the gear is attached to the cable if it looks good then put it back together and remove your cluster (speedo and other gauges inside) I suggest you pick up a repair manual at a big auto store on MK1-MK2 vdubs (82-92) to explain how to remove speedo cable from back of cluster its kinda of tricky getting your fingers back there and pressing it together to get it to release. Once out drive the car and see if that cable is turning from the inside if it is then its your speedo gauge that is faulty. Grab a cluster from a scrap yard, if that cable is NOT turning then the gearing inside the trany is messed up which would mean taking the trany apart to repair it. If that was the case you would be cheaper to replace the whole trany with a used one. Good luck

Vdubs 4-ever

Feb 24, 2009 | 1991 Volkswagen Golf

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