Re: gears click loud is it normal?
The forward and reverse gears have a drive dog that will engage into the face of the gears opposite the tooth side of the gears. The part of the dog and gear that lock together and drive the gears are nothing more than 3 equally spaced keyways that ramp down an angled surface until they catch the flat faced area and lock into position and drive the gear. If you let them grind too long, the flat faced area will start to wear and angle into itself and will ride up out of position. This will cause the grinding you are hearing. If yours does lock in, you are o.k. If it wont stay in, you can do like I did and machine the dog and both gears so the driving face is square again. I saved $100's by doing this. The gear teeth on my gears are in great condition, but the drive keys were trashed. A couple hours on a milling machine, a carbide end mill and a dividing head is all I needed. If anyone else is interested in this repair, please feel free to contact me.
Thanks