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problem solved! i took a closer look and found the 2nd/high fork went in but not the 1st /rev. on closer exam i found the sliding gear was sloppy on the shaft. i had several good used gears a friend had donated and used the best looking one. i had another gear with some surface rust that cleaned up easily in the bead blaster. i put that one in and everything went together smoothly. maybe that gear was out of a diffrent tranny, but it looked good except for not fitting the shaft well and not accepting the fork.