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[copout221]

So it looks like I just made one of the biggest mistakes as a Harley Owner. I decided to use a private mechanic to install my new 30T sprocket with drive belt. I dropped off the bike on Monday 8/22/2011 and it was running perfectly. The mechanic called me today and said "We have a problem" so I was extremely concerned. He told me that there was something now wrong with my transmission and he was unsure if he caused it or it was an existing problem. He described the problem as a loud grinding and I thought he was referring to the clutch chatter I have always experienced with this bike. I asked him to change the transmission fluid and he called me back to say that the fluid was gold in color and that something was coming apart in the transmission (see attached picture).  After arriving at his house I paid him (Yes, he took my $300.00) and began to ride off. As soon as I attempted to accelerate I heard what sounded like gravel being poured into a metal can. I immediately stopped, turned around, and returned to the mechanics house. After explaining that the noise was NOT pre-existing he was unable to provide me with an explanation or a solution so I was forced to call the dealer for a tow. The bike is now unrideable and I totally regret having this mod done by someone I don't know or have never met. 

If anyone knows what may have happened to my transmission from a sprocket installation please reply so I can try to understand myself. I do know this, he was having a difficult time removing the sprocket nut and had to seriously force it off. He almost had to cut it off but was able to get it loose after getting some help from a friend (or 2).

Picture of what he found after the installation



This is what I found after draining his fluid that he just put in a few hours ago. I only drove the bike for 2-3 minutes.

[hogasm]

Maybe went the wrong way with the nut

[HOGMIKE]

If your mechanic did not have the proper tools to do the switch, it would be very difficult.
It IS possible to damage the mainshaft with improper procedure, which may or may not be the case.
JMHO, of course.
You will have to pull it apart again to at least check transmission......sucks, but, if you have noise......well........
 

[Twolanerider]

Maybe went the wrong way with the nut

That was my first thought.  Didn't realize there were left handed threads out there and beat hell out of the mainshaft with an impact or breaker bar.  But a guy would have to be incredibly stupid, not just abnormally stupid but incredibly stupid, not to realize something unusual was going on there before he tore something up.  Not to beat someone while they're down; but have to wonder how much "savings" were had by taking a $30k+ bike to a guy with no shop, improper tools and no known reputation?

[Texas 103]

That was my first thought.  Didn't realize there were left handed threads out there and beat hell out of the mainshaft with an impact or breaker bar.  But a guy would have to be incredibly stupid, not just abnormally stupid but incredibly stupid, not to realize something unusual was going on there before he tore something up.  Not to beat someone while they're down; but have to wonder how much "savings" were had by taking a $30k+ bike to a guy with no shop, improper tools and no known reputation?

Made than same mistake with a local here but he was a very experienced Harley wrench, he installed a 6 speed gear set in my old Autumn Haze, broke the bearing retainer in the case, gear set moved, took out the whole gear set, got to buy a whole new trans..Oh well..

[Twolanerider]

Made than same mistake with a local here but he was a very experienced Harley wrench, he installed a 6 speed gear set in my old Autumn Haze, broke the bearing retained in teh case, took out the whole gear set, got to buy a whole new trans..Oh well..

That's a huge bearing.  I've seen cases against which someone hooked up the bearing puller the wrong way and broke the case with the case failing before any real harm was done to the bearing.  It takes a lot of experience to screw up that bad Greg .

[HOGMIKE]

That's a huge bearing.  I've seen cases against which someone hooked up the bearing puller the wrong way and broke the case with the case failing before any real harm was done to the bearing.  It takes a lot of experience to screw up that bad Greg .

IMHO, it would help if you read the service manual for your bike!
This applies to the independents, also. There ARE changes through the years!
just my 2c
 

[Ghost__Rider]

I would guess he twisted the mainshaft trying to get the nut off the wrong way. I've done four pully swaps and no problems. I would think he is liable for the damages. Like HogMike says, He should have read the manual!!! With the right tools it's a relatively easy job.

[Keats]

That's a huge bearing.  I've seen cases against which someone hooked up the bearing puller the wrong way and broke the case with the case failing before any real harm was done to the bearing.  It takes a lot of experience to screw up that bad Greg .

Don,

Do you think Duane might see this post?

[Twolanerider]

Don,

Do you think Duane might see this post?

Don't remember Duane's failure.  But a buddy north here in Kansas City did exactly that (with my borrowed tools).  Busted the case like Roseanne's pants after an all you can eat rib buffet.  Though the bearing itself showed no visual signs of distress.

[Keats]

Don't remember Duane's failure.  But a buddy north here in Kansas City did exactly that (with my borrowed tools).  Busted the case like Roseanne's pants after an all you can eat rib buffet.  Though the bearing itself showed no visual signs of distress.

I am sure Duane wanted to put this away forever, but he was kind enough to share his pain when he installed the Baker DDS6.

bent tools and all

[Keats]

more

[Keats]

A cheap lesson for me.......


Had I done this to my bike, I would not have spoke of this for weeks........

Thanks Duane for the orig post,

 Now I am pretty sure this will never happen to me

[RayG]

Wow, that is a tough lesson to learn.  I'm not very experienced with working on my bike and my mechanical abilities are average at best.  I read the complete post on the subject, called Steve for some much appreciated advice, read the manual and borrowed the tools necessary.  Maybe I was just lucky but I had no issues with doing the 30 tooth sprocket conversion.  Steve told me he did his in about 2 hours, being very challenged I needed 7 hours.  I was even quicker when the belt broke after 3000 miles.  Someone was not using common sense to do that kind of damage.  Hope things work out for you. 

[copout221]

Update:

The mechanic I took my bike to was referred to me by 7 other friends who have used him for everything from basic exhaust / tune / and high flow filter installs to engine rebuilds. I thought he would be more than qualified to work on my machine and he never led me to believe he did not have the expertise to perform the work requested. I am very mechanically inclined but decided to use a qualified mechanic (at least I thought he was qualified) rather than tackle the job myself since he quoted me 4 hrs @ 42.00 per hour (even though he charged me for 5 hours since he was probably trying to get the sprocket nut off the wrong way  ) and I would have paid more than that for a service manual and the tools. I should have just done it myself, I am seriously kicking myself now 

The bike is being picked up tomorrow by a local dealer and they will tear it apart on Sunday or Monday to inspect what happened. Every tech I spoke with today (including Steve from Fullsac) verified that the mechanic is absolutely responsible for what occurred and should step up to the plate like a reputable businessman. I already tried to call him today without a return call and will give it one more attempt after the bike is torn apart and the damage can be photographed (for legal reasons) and the estimate can be put together. My dealer cannot submit this for warranty since the damage is most likely not a common failure of the components. They did assure me that they would attempt to work the warranty issue if it looked as though the damage was NOT caused by the sprocket install but they are 99% sure it was due to negligence and/or lack of knowledge.

[Ghost__Rider]

I  hate it for ya. Everyone one makes mistakes. Only difference is some of us admit them, some don't. Good luck. If it is any constellation, you will love the sprocket once you get the bike fixed.

[copout221]

Can someone with a service manual confirm that the sprocket nut is a LH thread ? The mechanic called me and provided these images from his manual which clearly says it's a RH thread.

[HOGMIKE]

Sprocket nut is a right hand thread for 2010. as per the service manual.
Sometimes there are on VERY tight, but, I use an impact tool and locking device, and they WILL come off.
JMHO
 

[grc]

The older bikes, including my 2005, have a left hand thread on the sprocket nut.  When Harley changed to the Cruise Drive trans on the '06 Dyna, the nut and shaft were changed to a right hand thread.  If someone who last worked on a five speed were to assume the nut was still a left hand thread, I could see how they might beat the snot out of the trans trying to further tighten the nut before they finally figured out they were going the wrong way. 

The bike was running fine with no trans issues before the guy worked on it.  He admitted there was something wrong after his work when he called you before you picked it up.  I don't see where there is any question as to who has liability here. 

Good luck.


Jerry

[sadunbar]

The older bikes, including my 2005, have a left hand thread on the sprocket nut.  When Harley changed to the Cruise Drive trans on the '06 Dyna, the nut and shaft were changed to a right hand thread.  If someone who last worked on a five speed were to assume the nut was still a left hand thread, I could see how they might beat the snot out of the trans trying to further tighten the nut before they finally figured out they were going the wrong way. 

The bike was running fine with no trans issues before the guy worked on it.  He admitted there was something wrong after his work when he called you before you picked it up.  I don't see where there is any question as to who has liability here. 

Good luck.


Jerry

Jerry's statement is the bottom line, regardless of right hand vs. left hand thread.   

(Your's is right hand, as Jerry has pointed out).

[copout221]

The mechanic called me back this morning and assured me that he would accept all of the responsibility and will take care of all of the financial obligations that may arise. He continues to apologize and asked if he could come an take a look at the damage after the trans is torn apart so he can try to understand what he did wrong. He even offered to pay for a rental bike but I declined.

The bike was picked up this morning (see pic) and I'm hoping they can take a look at it sometime tomorrow or Monday.

Just out of pure curiosity, how much could this ultimately cost ? I cannot find the prices for newer transmissions or gearsets in my parts catalog.

[grc]

Try this web site to check parts prices:
http://partsfinder.onlinemicrofiche.com/ronnies/hdm_oem/hdmc.asp

Complete Trans is roughly $1400, the case alone is approximately $400, etc.


Jerry

[MAT]

Good news that the mechanic is stepping up to the plate, less of a heart ache for you. We all make mistakes and it sounds like he wants to learn from his.     MAT

[Texas 103]

Update:

The mechanic I took my bike to was referred to me by 7 other friends who have used him for everything from basic exhaust / tune / and high flow filter installs to engine rebuilds. I thought he would be more than qualified to work on my machine and he never led me to believe he did not have the expertise to perform the work requested. I am very mechanically inclined but decided to use a qualified mechanic (at least I thought he was qualified) rather than tackle the job myself since he quoted me 4 hrs @ 42.00 per hour (even though he charged me for 5 hours since he was probably trying to get the sprocket nut off the wrong way  ) and I would have paid more than that for a service manual and the tools. I should have just done it myself, I am seriously kicking myself now 

The bike is being picked up tomorrow by a local dealer and they will tear it apart on Sunday or Monday to inspect what happened. Every tech I spoke with today (including Steve from Fullsac) verified that the mechanic is absolutely responsible for what occurred and should step up to the plate like a reputable businessman. I already tried to call him today without a return call and will give it one more attempt after the bike is torn apart and the damage can be photographed (for legal reasons) and the estimate can be put together. My dealer cannot submit this for warranty since the damage is most likely not a common failure of the components. They did assure me that they would attempt to work the warranty issue if it looked as though the damage was NOT caused by the sprocket install but they are 99% sure it was due to negligence and/or lack of knowledge.

If he chooses not to step up like he should, might find a good attorney to send him a nice letter to help him with his amnesia.

[dlaws01]

Just a note.  As an aircraft maintenance technician, if I screw it up, I pay to have it repaired.  Otherwise, I would never have repeat customers.  We can all make mistakes, its how we respond to those mistakes that separates the professionals from the amateurs.

[Gettinold]

Just a note.  As an aircraft maintenance technician, if I screw it up, I pay to have it repaired.  Otherwise, I would never have repeat customers.  We can all make mistakes, its how we respond to those mistakes that separates the professionals from the amateurs.

[copout221]

Ok, dealer called and said that all or part of the trans cap dipstick came loose and fell into the trans. They said it would be covered under warranty with a $50.00 deductible. Is this something that others have had happen ? It seems awful coincidental that this happened at the same time I had the sprocket changed. As for the exact parts being replaced, I should know that tomorrow.


Sent from my iPad using Tapatalk

[MAT]

Wow, good news for the Mechanic!! Hope they just put a new tranny in and call it a wash.

[copout221]

Wow, good news for the Mechanic!! Hope they just put a new tranny in and call it a wash.

All they said was I needed $800.00 worth of parts and that the extended warranty was going to cover it. I judt hope that it's all done before the weekend.






Sent from my iPad using Tapatalk

[MAT]

I'm sure it will be fine, but a brand new bike deserves a brand new tranny- call it a piece of mind for the Owner. I hope all goes well. 

[copout221]

I'm sure it will be fine, but a brand new bike deserves a brand new tranny- call it a piece of mind for the Owner. I hope all goes well. 

They are not putting a new gearset in since there is no visible damage to them. They are replacing a bunch of seals and bearings that may have metal shavings in them. Otherwise, ESP is covering it minus my deductible. Hope to be back on the road this weekend.

[MAT]

They are not putting a new gearset in since there is no visible damage to them. They are replacing a bunch of seals and bearings that may have metal shavings in them. Otherwise, ESP is covering it minus my deductible. Hope to be back on the road this weekend.

Sounds like a good out come, I hope they do a good job on your bike. I will be paying attention to the condition to my oil dip stick for sure.
 Thanks for the updated info.
                               

MAT

[copout221]

Found out today that the trans case is cracked. This just keeps getting better

[MAT]

Sounds like it should just be a new trans. after all.

[copout221]

Well they said all of the gears are fine but it is getting a new main drive gear assembly, all new seals, new case, new bearings, etc.

Turns out to be the private mechanics fault. The case is actually broken around the main drive gear.

[copout221]

Here is a picture of the broken dipstick. Still unknown how this happened but it was NOT like that prior to bringing the bike to the private hackanich.

[Fullsac Performance]

Wow. I've heard story's of the replacement oil temp dip sticks falling apart. Never heard of a tranny dip stick falling apart.
Those things are pretty stout. Best of luck with this one.

Steve

[MAT]

Wow. I've heard story's of the replacement oil temp dip sticks falling apart. Never heard of a tranny dip stick falling apart.
Those things are pretty stout. Best of luck with this one.

Steve

Yes, It almost seems like MAYBE someone was trying to cover something up!     

[timtoolman]

used to be a problem on 5 speed bikes,  tranny dip sticks breaking off.

[copout221]

It actually looks like the main shaft snapped it off after the clutch was released since the drive gear was not being supported by the case any longer. When the clutch was disengaged it would apply pressure to the drive gear against the case but when the clutch was engaged the main shaft was just coming loose and causing damage.

[sadunbar]

It actually looks like the main shaft snapped it off after the clutch was released since the drive gear was not being supported by the case any longer. When the clutch was disengaged it would apply pressure to the drive gear against the case but when the clutch was engaged the main shaft was just coming loose and causing damage.

Is the warranty still being applied to the repairs?   

[copout221]

Is the warranty still being applied to the repairs?   

An adjuster came out and initially wanted to deny the claim but after looking at everything he was not able to positively blame the case failure on the sprocket installation. What may have saved me was my previous documented complaints of a noisy trans between 2500-3500 RPM's that was discarded as normal. They asked me about that a few times and my service writer seems to think the trans case may have already been on it's way out the door before the sprocket installation.

[sadunbar]

An adjuster came out and initially wanted to deny the claim but after looking at everything he was not able to positively blame the case failure on the sprocket installation. What may have saved me was my previous documented complaints of a noisy trans between 2500-3500 RPM's that was discarded as normal. They asked me about that a few times and my service writer seems to think the trans case may have already been on it's way out the door before the sprocket installation.

That's good for both you and your Indy...   

[MAT]

That's good for both you and your Indy...   

   X  2

[copout221]

So now that the bike is back in my hands and running great. I contacted the mechanic via telephone who damaged the transmission and asked for all of the labor charges back. He flat out denied my request and stated "I am standing behind my work" which I found both amusing and disturbing. I basically told him that his work was responsible for the damage to the case which caused additional damage inside the transmission. He did not dispute that his work was responsible for the damage and offered to reimburse me for the warranty co-pay, 1 hour of labor, and the tow cost of $80.00. I sent him an email earlier this week asking for all of the labor, the tow cost, and the co-pay which comes to a total of $340.00. I did NOT ask for a refund for the parts he provided like the clutch spring, gaskets, seals, and fluids but I do think he should refund all of the labor that I paid him. Especially since I was left without my machine for 3 weeks and missed two very important rides.
He has NOT responded to my email and has not responded to a text message I sent earlier today to verify he did recieve the email. My next step will be a small claims lawsuit against him and his home based business which he will not win. As soon as I know what direction I am heading regarding this matter I will post this mechanics name along with his business name on every V-Twin forum I can find so others don't get screwed like I did.

[timtoolman]

Soooo what did the independent mechanic do wrong??? that caused the whole problem that the dealer covered under warranty??  don't be so sure he wont win the law suit.  Can you prove the damage was done by him and him alone with no doubts  . a counter suit may follow to you for defamation/slander especially since dealer covered it under warranty, Because a sharp lawyer would  get a affidavit from another dealer saying if the was damage done by another unauthorized  mechanic beyond a doubt  the other dealer wouldn't have covered the repair?.  just something to think about before jumping

[copout221]

Soooo what did the independent mechanic do wrong??? that caused the whole problem that the dealer covered under warranty??  don't be so sure he wont win the law suit.  Can you prove the damage was done by him and him alone with no doubts  . a counter suit may follow to you for defamation/slander especially since dealer covered it under warranty, Because a sharp lawyer would  get a affidavit from another dealer saying if the was damage done by another unauthorized  mechanic beyond a doubt  the other dealer wouldn't have covered the repair?.  just something to think about before jumping

Well here are some of my points:

1. The bike ran perfectly before dropping it off at the private mechanics house.

2. The work that was done can easily be tied to the damaged transmission case. It's not like the gauges stopped working after a trans sprocket was changed.

3. Two HD mechanics assured me that the damage could have easily been caused by improper removal of the sprocket nut. They are willing to appear on my behalf if needed.

4. The private guy admitted that the damage was most likely his fault. He even called me on the 2nd day of having it and said he could NOT get the sprocket nut off and had to "Force the s**t" out of it after borrowing a special tool  (Updated mainshaft locknut wrench tool HD-47910).

5. The transmission damage was apparent IMMEDIATELY after the sprocket change. It's not like the bike ran perfectly for 200 miles and then the case broke.

6. ESP covered the damage thanks to the dealer helping me out. At first they did not attribute the broken dipstick to the sprocket swap but after they discovered the broken transmission case while removing the drive gear they said there was no doubt that the damage was due to carless / improper removal of the sprocket nut.

[copout221]

I am sure Duane wanted to put this away forever, but he was kind enough to share his pain when he installed the Baker DDS6.

bent tools and all

This is EXACTLY what happened to my trans case. My guess is he was trying to remove the nut thinking it was a LH thread 

[djkak]

This is EXACTLY what happened to my trans case. My guess is he was trying to remove the nut thinking it was a LH thread 

On this end of the ether, it looks a lot like something else was going on. The photos of Duane’s transmission give us some idea of the thrust force necessary to fracture this shoulder on a 5-speed transmission housing. The force was substantial enough to put a serious bend in a piece of 5/8” steel plate. When the housing snapped, the main drive gear struck the plate hard enough to leave gear tooth imprints in it.

I’m thinkin’ that it would be pretty tough to pull this off with a Binford 1” drive Torque Master Socket Set. I can visualize the torque, but I’m strugglin’ to understand the thrust.

Regarding the broken dipstick, if you try to remove the 6-speed gear set without first removing the dipstick, you will break the dipstick. Hard to say what really happened here.  There is no need to pull the gear set to replace the drive sprocket. Either way, this would have been some big fun to watch, I’m sure!


Click on the photo to view it actual size.

[copout221]

The broken dipstick was discovered BEFORE they pulled the gearset so that was not how it broke. The gear set DOES have to be pulled to remove the drive gear, that is how they discovered the broken case. The private mechanic NEVER removed the gear set while doing the sprocket change. He just managed to crack the trans case.

I received a full refund from the mechanic yesterday so this matter is now closed. He reimbursed me for all of the labor i paid him for the sprocket and belt install, the tow fees, and the ESP co pay. He has apologized several times and there is no need to beat a dead horse. I learned a valuable lesson and will be more careful in the future.

[MAT]

The broken dipstick was discovered BEFORE they pulled the gearset so that was not how it broke. The gear set DOES have to be pulled to remove the drive gear, that is how they discovered the broken case. The private mechanic NEVER removed the gear set while doing the sprocket change. He just managed to crack the trans case.

I received a full refund from the mechanic yesterday so this matter is now closed. He reimbursed me for all of the labor i paid him for the sprocket and belt install, the tow fees, and the ESP co pay. He has apologized several times and there is no need to beat a dead horse. I learned a valuable lesson and will be more careful in the future.

Very good news, glad that part worked out good!   

[Twolanerider]

There is no need to pull the gear set to replace the drive sprocket.

The gear set DOES have to be pulled to remove the drive gear

Main gear versus sprocket.  

[Dan_Lockwood]

I know that this issue is dead now, but I do have a question about this breakage issue.

Maybe I don't know all the in's and out's of the mainshaft in the tranny, but most transmissions are set up so there is a certain amount of end play or preload on the shaft and bearing.  This is true for all types of transmissions.

When the output drive belt drive sprocket is pushed onto the spline of the output shaft of the transmission, it has to bottom up against something and stop; a should on the shaft or a spacer that goes into the transmission and hits a gear machined on the shaft itself.  Something stops and aligns the belt drive sprocket for proper alignment...

The only use for LH or RH threaded nuts is to work against rotation of a particular shaft to combat possible vibrational loosening of the nut.

So whether LH or RH, if you over torqued the nut when tightening it or trying to loosen the nut but turning it the wrong way, this would only put a twisting load on the shaft itself or any holding tool/fixture to hold the sprocket firm while removing the nut.

My question is this:  How does turning the nut the wrong direction pull outward on the main shaft enough to pull the bearing through the side and breaking the case as in the pictures in this thread?

[djkak]

I know that this issue is dead now, but I do have a question about this breakage issue.

Maybe I don't know all the in's and out's of the mainshaft in the tranny, but most transmissions are set up so there is a certain amount of end play or preload on the shaft and bearing.  This is true for all types of transmissions.

When the output drive belt drive sprocket is pushed onto the spline of the output shaft of the transmission, it has to bottom up against something and stop; a should on the shaft or a spacer that goes into the transmission and hits a gear machined on the shaft itself.  Something stops and aligns the belt drive sprocket for proper alignment...

The only use for LH or RH threaded nuts is to work against rotation of a particular shaft to combat possible vibrational loosening of the nut.

So whether LH or RH, if you over torqued the nut when tightening it or trying to loosen the nut but turning it the wrong way, this would only put a twisting load on the shaft itself or any holding tool/fixture to hold the sprocket firm while removing the nut.

My question is this:  How does turning the nut the wrong direction pull outward on the main shaft enough to pull the bearing through the side and breaking the case as in the pictures in this thread?

The components are the Mainshaft, which the clutch is fastened to and the Main Drive Gear, which the transmission final drive Belt Sprocket is fastened to.

The Mainshaft, Main Drive Gear and Countershaft, are all mounted in ball bearings which control the non adjustable endplay of these components.

The alignment of the transmission’s belt sprocket is controlled by a large spacer that fits between the Belt Sprocket and Main Drive Gear ball bearing.

All of this background is somewhat irrelevant to the question, though; increasing the torque of the nut securing the Belt Sprocket to the Main Drive Gear, beyond the fastener’s capacity, will simply pull the threads on the nut, the Main Drive Gear or both.

Look at the pictures again; in order to break the transmission housing in this manner, the Main Drive Gear must thrust horizontally to the right, and with extreme force. If it was possible for the Belt Sprocket fastener to continue drawing the sprocket and MDG together, the MDG would be pulled to the left, not the right.

FWIW, copout’s issue has been put to bed, but my interest in this thread is not with who did what and when, but to offer a little pushback to the assertion that applying excessive torque to the Belt Sprocket fastener will break the transmission housing as pictured; from that perspective this thing is just getting started.

[sadunbar]

The components are the Mainshaft, which the clutch is fastened to and the Main Drive Gear, which the transmission final drive Belt Sprocket is fastened to.

The Mainshaft, Main Drive Gear and Countershaft, are all mounted in ball bearings which control the non adjustable endplay of these components.

The alignment of the transmission’s belt sprocket is controlled by a large spacer that fits between the Belt Sprocket and Main Drive Gear ball bearing.

All of this background is somewhat irrelevant to the question, though; increasing the torque of the nut securing the Belt Sprocket to the Main Drive Gear, beyond the fastener’s capacity, will simply pull the threads on the nut, the Main Drive Gear or both.

Look at the pictures again; in order to break the transmission housing in this manner, the Main Drive Gear must thrust horizontally to the right, and with extreme force. If it was possible for the Belt Sprocket fastener to continue drawing the sprocket and MDG together, the MDG would be pulled to the left, not the right.

FWIW, copout’s issue has been put to bed, but my interest in this thread is not with who did what and when, but to offer a little pushback to the assertion that applying excessive torque to the Belt Sprocket fastener will break the transmission housing as pictured; from that perspective this thing is just getting started.

Of course, DJkak is correct...  More had to have transpired than is known.   



That being said, I am glad that copout's issue is fully resolved to his satisfaction.

[porthole]

Don,

Do you think Duane might see this post?

He might 

Discussions I had with a fairly reputable indy that some here might know, I believe the failure on my case was excessive friction between the bearing and the shaft.
I think it may even have had red loctite on the shaft.

When pressing the shaft out with the pictured tools you are using the bearing, while seated in the case, as a support. So all the pressure on the shaft is transmitted from shaft - to inner race - to bearings - to outer race - to case land.

There is not enough meat in the case to support this kind of pressure. The trick seems to be to heat up the bearing first, to help the bearing separate form the shaft.