Just bought an '02 with ABS Just discovered lots of rotational play at f.sprocket I removed sprocket(marked "MCW") and discovered the splines in the sprocket are almost gone and the shaft splines are "somewhat worn" I'll get a new OEM sprocket for it My questions are: can /should anything be added to the splines during install tp tighten things up(ie Permetex bearing mount or dare I say it.......JB Weld)or do I need to replace the transmission counter shaft? Is there supposed to be a shim between the sprocket and shaft collar to eliminate the in and out(axial) free play of the sprocket when bolt is tight?
If it were me, I would get a new sprocket and see how sloppy it fit on the countershaft. If the radial play isn't awful but the rotational (?) play was, I'd probably try individual pieces of shim stock (bronze or low carbon steel) on each spline placed on the driven side of the sprocket (I hope that makes sense). The softer shim material would tend to form itself to the irregularities of the mating surfaces. JB Weld might not hold up too well, and it would be a pain trying to evenly distribute it. And if the JB DID adhere really well, removing the sprocket in the future could be interesting. From a purist standpoint, the countershaft should be replaced, of course. I'd try a workaround just because it might work, and you'll be no worse off if it doesn't.