Finally got the Phazer put back together with a 153" x 14 1/4" today. CR Racing now has some awesome rail extensions that Chad machined up for me. They are available for sale as well and will also work for a 153" to 162" swap. One less project to do come winter.
I thought I was done but noticed a mystery oil leak, so apart it came. Heard of other people having this problem, but never got a solid answer. Turns out the reverse box is lubricated by a small "funnel" that catches oil thrown off the top gear in the chaincase. That oil is then fed 90 degrees through the bulkhead and drips down into the reverse box. When the sled is stopped, the oil then bleeds through the bearing back into the chaincase. Not a bad idea because the top bearing actually gets lubricated. The problem is the "funnel" and the rubber grommet are not long enough on the '07's. The '08 and newer is an 1/8th inch longer, which ensures the oil doesn't run down between the reverse box and the bulkhead. I ripped mine completely apart to check everything but if someone else has this problem, it's easily fixed by just going in as far as the chain case. If you've never run it low on oil, your reverse box should be fine. While you're in the chaincase, check the 6mil bolts that go through the chaincase and bulkhead into the reverse box. Mine were a little loose and that has to be tight to ensure that the "o" ring is sealed. If that "o" ring needs to be replaced, it's a big job, the reverse box has to be pulled. My buddy has 3 of these sleds and we checked them, 2 are leaking in the same spot. He never noticed as he parks them for the summer in his barn with a dirt floor. Seems to be a fairly common problem, but an easy enough fix and only $35 for the "funnel" and grommet. If anyone has this problem and needs help, pm me, I'd be glad to help talk you through it. Ran it up several times on the track stand, no more leak. Hope this helps someone as the local dealer hadn't even heard of it.
