I pulled things back apart today to see if I could find anything out of place. The clutch dogs look okay to me, but there are others here who know better and might tell me different:
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The one thing I did find, mostly just because it cut my finger, is that the ring around the bottom of the timing belt splines (timing pulley clutch sleeve, I think) has been mushroomed out to a very sharp edge- it may be difficult to see in the picture. Have I been bottoming the sleeve out against the bull gear? If that surface has been riding against the bull gear, could that cause the clutch dogs to knock against each other?
The one thing I did find, mostly just because it cut my finger, is that the ring around the bottom of the timing belt splines (timing pulley clutch sleeve, I think) has been mushroomed out to a very sharp edge- it may be difficult to see in the picture. Have I been bottoming the sleeve out against the bull gear? If that surface has been riding against the bull gear, could that cause the clutch dogs to knock against each other?