Full Floater

In my 78 RS600L, I have an EM6-300. Not the original engine and im not sure what the original engine was. I have an electric fuel lift pump mounted behind the fuel filters that is energized by the ignition ON. Is this a factory lift pump? Its working just fine and makes priming the system and fresh filters a breeze. Just curious Don't mind the red wire...that's just a mickey mouse and temporary ground for a marker light I had to jimmy rig recently.

Have you tried replacing the air supply spin on filter? Seemed to help a little when I was (still am) having issues with the reverse selector. Damn now im paranoid about those bolts. Did I tighten them enough??? hmmmm

Did they come out of a Hayes off roader or something? Just curious. I had one, 68 HDX with a 12v71 that came from Rupert

Im thinking that its either a sticking locking pin or an air blockage/pressure issue. When the cover is off, everything seems to be fine, as long as the high-low is in its neutral position, the reverse ram will work well. This is with air and not touching the ram itself. Yeah maybe there is silicone somewhere. I put a THIN layer on the first time I set the lid on but I let it set up mostly before I set the lid on, then once I realized I was going to be taking that thing on and off a few times, I cleaned off all the silicone with a rag so it wouldn't start making a mess. I was careful not to get any in the gearbox

Good to know, thanks. I'll check that out. I cant hear any air escaping but who knows.

Ok I got it!! I ended up using a screwdriver as you described and the selector is now working as it should, thanks! however; im kinda back to the same problem. When the trans has warmed up, it becomes very stubborn to get reverse again. Today when I test drove it, all was well so I went and did a load, and about 10 miles into the run, no reverse for the life of me. If I had tools with me I would have popped that cover now that im familiar with it but I didn't have any tools really. So I attempted to pour cool water on it for a while to get the temp down (it was just barely warm), that did nothing, I tapped it with a hammer a bunch and that's when I finally got it to engage. Which was good because I was faced into a dead end road. I engaged and disengaged it a number of times to try and free something up , then 5 miles later, same thing, no reverse. But after working the toggle a bunch and rocking the truck back and forth, it engaged. Then on the way home it was ok, not that easy but there was not much fighting to get it to engage. And that's where I left it now that darkness is upon us. I made sure I was at or over 100lbs of air, the filter is new, there is tons of pressure at the air line when its disconnected and the inlet fitting is free of obstructions. So, im 99.9% sure that it is getting all the air it needs. I lightly coated the rams and all the orings with grease when I installed them to lube everything up nice.

Wow thanks for taking the time to scan those pages. I didn't know about that adjustment procedure. I'll save that part for later and I'll make sure those forks are in those positions, which I don't think they were; tomorrow morning. Thanks! And yeah, another day id like to hear that story of the bolt falling off. So id better double check that they are tight!!

Yeah that's what I would like to try. And to select neutral on the shift forks in the trans, what am I looking for? Do I just want the forks to sit freely? The trans and selector were in neutral when I removed the cover, and im attempting to assemble with the shifter and selector in neutral. So I guess all that im looking for is the forks to be in neutral to now... I think..

With the Hi Lo selector in the middle (locking pin) position, the reverse ram will move to the reverse position when air is applied to the side port. And back to neutral when air to the rear port. When the reverse ram is in neutral, the Hi Lo will function properly also. Do the selector forks in the trans have to be in a specific position when installing the cover?

Nevermind, now I can move it, just had to reposition the other one in order to allow the reverse one to move

I was able to peak through as I was lowering the lid to ensure that the doo hickeys were in there slots. I have the cover off again, I cannot move the neutral reverse doo hickey/ram at all. I noticed this a I put it on to but just didn't think much about it. I think it may be an issue with the locking pin?? As I kind fiddled with it to get the rams back in

Ok so I got it all back together, replace every oring and slapped it back on the trans. Hooked up all the air lines correctly, and Im not getting neutral or reverse at all now. Hi and lo work but every selection on the splitter including neutral and reverse is forward. So im going to pull it back off and see what I can find.

Once again you have an encouraging response, many thanks! I will be back working on it again in the a.m. I will try to push the smaller cylinder out, I did try a bit but as it wouldn't budge I left it alone until I found out more. I'll make a proper attempt now. Ah ok, now that I look at that piece again, it makes sense. Didn't even realize the air line didn't have it inside.... That's nice to not worry about that.. You will hear back from me soon.

Ok so im finally getting around to working on it. Pulled the top cover off no problem, lots of room. I noticed that on the reverse cylinder, the air fitting on the square top cover is loose. I have attached a picture of it. I can wiggle it to the point where it will come right out. Could this have been my issue all along? I understand that this is not the supply line for reverse but still wondering. I could not hear air escaping at any time however. If this is a problem, does anyone have the part number for these fittings? I suppose it may snug up with the line attached; but thought id ask anyways. And I started on the hi-lo cylinder and im REALLY struggling with this internal snap ring. I have attached a picture of it also. I had to leave it for today due to frustration. Are there any tricks for that one? Im feeling like I want to leave the remainder of that cylinder alone as the hi lo was working fine. I have neatly placed all parts that I have removed, in order on a clean table but im not yet seeing all of the o-rings that I got in the kit. They must be down deeper in the hi-lo cylinder im guessing. And am I safe to use brakeclean to clean everything up in there? ...if all the orings are getting replaced that is..

So its the entire top cover that comes off?? then the cylinders can be dismantled? Sorry, dumb question

Should I have the selector in Neutral for disassembly?

Ok I ordered that kit, waited patiently for it and oh boy....its here!!!!! Is this what im needing? Its a whole LOT of orings!!!! Now im scared.....

Thanks again!!

Yeah im going to have to do those orings quick. It won't engage at all when its hot now, once it cools down it seems to work fine. Got stuck today nosed into a wall and couldn't get it in reverse, had to come back later and try. Drove it home and same thing.

Ok so I replaced the air filter/breather and removed the air line from the round reverse cylinder and found lots of pressure from the air line when reverse was selected on the shifter, didn't even put a gauge on it as I no longer thought that pressure was an issue. I sprayed a little (not much) WD-40 down into the reverse cylinder in the air fitting, hooked the air line back up and reverse is now engaging first try again. Did one small job with the truck and it worked fine the entire time. So, im not sure if the breather may have been clogged or the WD-40 lubed things up a bit or both; but its working again. Im still going to order the o-ring kit just in case. Thanks again. I will stay posted with how it works over the next while.

So it the issue was in the switch. I swapped it out with another that I had kicking around and it worked first try. And the power divider is in fact working again. Thanks for the helpful suggestions

And another quick question....should the clutch be in (disengaged) or out (engaged) when attempting to select reverse? I have not been able to diagnose anything yet....darn work getting in the way.

And thanks for the part number

Ill check that, thanks

Thanks again Challenger!!! That will be next on the list once I figure out the reverse issue. Another thing that I just thought of is, I did engage the divider twice before I came to a complete stop. I was going slow, clutch disengaged so no load on it but I was moving. I realize the warning label says not to engage with vehicle in motion but I panicked