Don't wait long, that shuddering is your gearbox output splines going away and if you wait too long, it will be too late ....

NOt a good thing to put off.

Its not impossible to total one out by wrecking the output shaft. Or, a guy could be forced into learning how to split the cases & replace that shaft.
When the front pulley gets loose it eats the splines in the pulley faster than the ones on the shaft, but the shaft does suffer & will eventually get in such shape that even a new pulley wont fit right. If thats where you are then there are redneck & somewhat temporary solutions.I wouldnt just JB weld it, Id hunt down some shim stock to fill the gap between teeth in a coupla places & some piano wire to fit under the teeth to hold the pulley up & centered on the shaft. 3 spots would do that. Id rotate the new pulley as far clockwise on the shaft as possible, so acceleration would be metal on metal, deceleration would be compressing the JB weld,
Getting good results from redneck repairs requires some technique beyond just slapping epoxy on a problem.
If the OD of the shaft is okay, then the centering efforts wouldnt be needed. But I would want the pulley rotated hard against the splines so acceleration isnt compressing the JB weld. & that would somewhat protect the JB weld during deceleration,

IDK for sure that its even humanly possible to get things in there, but its what Id try.

Agreed. She's parked, but my back has been out for over two months, so I'll wake up feeling good one day and launch an all-out assault on the offending cog. I know many on here have similar or worse problems. We live in spurts.   But we get it done fast while we can. My Go Pro has been shipped for Santa. I can't run anymore and mounting a camera on the dash of my truck ain't gonna' get it. Fixing the Savage is a MUST. Happy Thanksgiving to you all.  

Justin, no chiropractor for me. Too many nerves being enclosed by Spinal Stenosis (Narrowing of the canal) BUT I just read your post on redneck repairs. I have assumed all along I can come up with something If standard procedures don't work.  

I started work today after riding up on 4" block and getting daughter to help with getting my Serowprop 2X4 mc stand under the engine. Pulley will slightly move behind tight nut. Looks to be maybe an eigth inch or so. Taking pics, but do not recommend my procedures. Paid $17.54 for 32mm impact socket, so I will be taking the pulley off once a week for a year to recoup my expense. Soaking in some space age solvent tonight. Have the 80 lb (Actual weight...not torque) HF electric impact. May get to take it off tomorrow. Things pop up, you know.  

Boofer wrote on 11/20/12 at 18:09:00:




Another $4.12 & you coulda had a whole set from Harbor Fruit,,