. slides/DSC_0080.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 This is the clean bearing block and the base of the shifter housing. A thin brass washer goes first (not shown), then the shifter housing base goes on top of that. It is easier if you disengage the little downshift pawl spring so that the pawl doesn't get in the way, you can put that back on last before the brake lever goes on. Same goes with the downshift (release lever) return spring. Next goes the thin washer with the tab. The tab points up, and in this left shifter, it goes toward the center of the bike. It can only go two ways. The center piece with the hook goes on next, then the spring, which fits very lose. (no lube shown for clarity, you should use the recommended lube on these pieces. This is the clean bearing block and the base of the shifter housing. A thin brass washer goes first (not shown), then the shifter housing base goes on top of that. It is easier if you disengage the little downshift pawl spring so that the pawl doesn't get in the way, you can put that back on last before the brake lever goes on. Same goes with the downshift (release lever) return spring. Next goes the thin washer with the tab. The tab points up, and in this left shifter, it goes toward the center of the bike. It can only go two ways. The center piece with the hook goes on next, then the spring, which fits very lose. (no lube shown for clarity, you should use the recommended lube on these pieces. slides/DSC_0080.JPG slides/DSC_0079.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 On top of the hook spring goes the second thin washer (the one with the round hole, not the cross shaped hole). Then the release mechanism frame (black metal piece shown.) Notice where the spring end hooks to. You can see the little brownish piece of spring sticking up by my index finger. On top of the hook spring goes the second thin washer (the one with the round hole, not the cross shaped hole). Then the release mechanism frame (black metal piece shown.) Notice where the spring end hooks to. You can see the little brownish piece of spring sticking up by my index finger. slides/DSC_0079.JPG slides/DSC_0077.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Next piece is the frame that holds the pawls that hold the shifter in a gear. Notice the bottom pawl (the thickest) is resting on the release mechanism frame tab that sticks up, while the smaller pawl is inside this tab. Use one finger to pull these away from the shaft while you put it in. You can use your fingernail to grab both of the pawl tips if necessary. Next piece is the frame that holds the pawls that hold the shifter in a gear. Notice the bottom pawl (the thickest) is resting on the release mechanism frame tab that sticks up, while the smaller pawl is inside this tab. Use one finger to pull these away from the shaft while you put it in. You can use your fingernail to grab both of the pawl tips if necessary. slides/DSC_0077.JPG slides/DSC_0078.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 This is a side view of the pawls. This is a side view of the pawls. slides/DSC_0078.JPG slides/DSC_0049.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 The next piece contains the gear return spring as well as the ratchet pieces that the pawls engage to. These hold the gear. Notice the hook shaped piece, that is where the cable goes through. The hook is the detent for the lowest gear. The next piece contains the gear return spring as well as the ratchet pieces that the pawls engage to. These hold the gear. Notice the hook shaped piece, that is where the cable goes through. The hook is the detent for the lowest gear. slides/DSC_0049.JPG slides/DSC_0050.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 This is a bottom view, you can clearly see the orientation of the ratchet. You'll notice the dot. It will only go one way if the dot faces out. For the smaller piece underneath, the beveled inner surface goes toward the larger gray metal piece. This is a bottom view, you can clearly see the orientation of the ratchet. You'll notice the dot. It will only go one way if the dot faces out. For the smaller piece underneath, the beveled inner surface goes toward the larger gray metal piece. slides/DSC_0050.JPG slides/DSC_0051.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Here's a top view of the spring installed. To install, just engage the straight radial spring stub on the outer housing but don't push all the way down so that the 90° stub (faces up) sticks up a bit. Engage the inner piece with this 90° spring stub, and turn counter-clockwise until the tab on the inner piece falls into its slot. It will stay like this. unless you push out the inner piece. Make sure to lube the pieces which I don't show for clarity. Here's a top view of the spring installed. To install, just engage the straight radial spring stub on the outer housing but don't push all the way down so that the 90° stub (faces up) sticks up a bit. Engage the inner piece with this 90° spring stub, and turn counter-clockwise until the tab on the inner piece falls into its slot. It will stay like this. unless you push out the inner piece. Make sure to lube the pieces which I don't show for clarity. slides/DSC_0051.JPG slides/DSC_0075.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Here is a side view of the ratchets and the spring housing. Here is a side view of the ratchets and the spring housing. slides/DSC_0075.JPG slides/DSC_0076.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 The other side. The other side. slides/DSC_0076.JPG slides/DSC_0074.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Push down the spring housing into the shaft. You may have to move the pawl shaft out of the way a bit, but you can also turn the spring housing a bit (like going to a higher gear) which makes it easy to clear the pawls. Just make sure you push down on the center piece of the spring housing, otherwise it will come out and you'll have to reinstall it. Use a sharp pick to pull the pawls out of the way, but you shouldn't have to use a lot of force. Install the cross shaped metal spacer. Push down the spring housing into the shaft. You may have to move the pawl shaft out of the way a bit, but you can also turn the spring housing a bit (like going to a higher gear) which makes it easy to clear the pawls. Just make sure you push down on the center piece of the spring housing, otherwise it will come out and you'll have to reinstall it. Use a sharp pick to pull the pawls out of the way, but you shouldn't have to use a lot of force. Install the cross shaped metal spacer. slides/DSC_0074.JPG slides/DSC_0073.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Now install the Flight Deck sensor. Hopefully you didn't move things around too much when disassembling. Pay attention to the little nubs on the bottom of the sensor. They should engage with the spring housing outer section. You may have to rotate the sensor a bit depending on what gear it was when you disassembled and where it is now. Now install the Flight Deck sensor. Hopefully you didn't move things around too much when disassembling. Pay attention to the little nubs on the bottom of the sensor. They should engage with the spring housing outer section. You may have to rotate the sensor a bit depending on what gear it was when you disassembled and where it is now. slides/DSC_0073.JPG slides/DSC_0072.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Here's a side view of the sensor installed. I also show the release lever return spring installed but you can hold off before installing it. Here's a side view of the sensor installed. I also show the release lever return spring installed but you can hold off before installing it. slides/DSC_0072.JPG slides/DSC_0071.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 I show this for clarity only. Before installing the metal piece on top of the sensor, you need to install the plastic housing. Note how everything fits. I show this for clarity only. Before installing the metal piece on top of the sensor, you need to install the plastic housing. Note how everything fits. slides/DSC_0071.JPG slides/DSC_0070.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Another view. Another view. slides/DSC_0070.JPG slides/DSC_0069.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 A third view. Note I have the release pawl spring installed. The pawl spring goes first, then the return lever spring. A third view. Note I have the release pawl spring installed. The pawl spring goes first, then the return lever spring. slides/DSC_0069.JPG slides/DSC_0068.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 One more shot from this side. You can never have too many views. One more shot from this side. You can never have too many views. slides/DSC_0068.JPG slides/DSC_0081.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 OK here I show the shifter plastic housing. Don't forget the back piece which I don't show. OK here I show the shifter plastic housing. Don't forget the back piece which I don't show. slides/DSC_0081.JPG slides/DSC_0082.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Now the metal piece that holds things together. The nut goes on top of that. Now comes the hard part. Now the metal piece that holds things together. The nut goes on top of that. Now comes the hard part. slides/DSC_0082.JPG slides/DSC_0083.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 This is probably what you heard letting go when you first took it apart. I didnt' have the Shimano spring installation tool and it was late at night so I just made something on my lathe to get me through. The Shimano tool is much thinner and will make this job much easier. Install the spring in the lever void such that the spring vertical stub goes through the small hole in the lever. This is probably what you heard letting go when you first took it apart. I didnt' have the Shimano spring installation tool and it was late at night so I just made something on my lathe to get me through. The Shimano tool is much thinner and will make this job much easier. Install the spring in the lever void such that the spring vertical stub goes through the small hole in the lever. slides/DSC_0083.JPG slides/DSC_0084.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 This is how it should look. (Except for the dog hair which gets everywhere--it was a clean old t-shirt when I started) This is how it should look. (Except for the dog hair which gets everywhere--it was a clean old t-shirt when I started) slides/DSC_0084.JPG slides/DSC_0085.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Next comes the tool. Shimano's tool is basically a small thin roll pin. I used a small bolt, drilled the center with a 5/64" bit and cut the head off. I had to turn it on the lathe to make it smaller than I show here. Trust me, just go buy the Shimano tool, or a thin roll pin...the smallest that will fit around the spring's wire. Next comes the tool. Shimano's tool is basically a small thin roll pin. I used a small bolt, drilled the center with a 5/64" bit and cut the head off. I had to turn it on the lathe to make it smaller than I show here. Trust me, just go buy the Shimano tool, or a thin roll pin...the smallest that will fit around the spring's wire. slides/DSC_0085.JPG slides/DSC_0086.html Sun, 17 Aug 2008 23:55:21 -0500 Jalbum 8.0 Put the lever on, start pulling on the lever to get you past the first obstacle, then keep pulling all the way back all the while holding things together. It has to go all the way back to the little tab to the left close to my thumb. Keep it together until you can put the nut on the lever. At this point you can follow Shimano's instructions. Sorry but those are all the pictures I have and I don't want to take this thing apart again. If you do the right shifter, and are able to put it back together, you can take pictures and post an album like I did to help others. I highly recommend taking multiple pictures from every angle you can think of before you take anything complex apart. Put the lever on, start pulling on the lever to get you past the first obstacle, then keep pulling all the way back all the while holding things together. It has to go all the way back to the little tab to the left close to my thumb. Keep it together until you can put the nut on the lever. At this point you can follow Shimano's instructions. Sorry but those are all the pictures I have and I don't want to take this thing apart again. If you do the right shifter, and are able to put it back together, you can take pictures and post an album like I did to help others. I highly recommend taking multiple pictures from every angle you can think of before you take anything complex apart. slides/DSC_0086.JPG