Mainshaft Thrust Clearance Adjustment
Mainshaft Thrust Clearance AdjustmentSpecial Tools Required
- Mainshaft holder 07GAJ-PG20110
- Mainshaft base 07GAJ-PG20130
1. Remove the 72 mm shim (A) and oil guide plate M from the transmission housing (B).
2. Install the 3rd/4th synchro hub (A), the distance collar (B), the 5th/6th synchro hub (C), distance collar (D), and ball bearing (E) on the mainshaft (F), then install the assembled mainshaft in the transmission housing (G).
3. Install the washer (H) on the mainshaft.
4. Measure distance (1) between the end of the transmission housing and washer with a straight edge and vernier caliper. Measure at three locations and average the reading.
5. Measure distance (2) between the end of the clutch housing (A) and bearing inner race (B) with a straight edge and depth gauge. Measure at three locations and average the readings.
Shim Selection Formula:
6. Select the proper 72 mm shim from the chart. Follow the example, and use the measurements you made in steps 4 and 5:
(Basic Formula)
(1) + (2) - (0.8 + 0.11) = shim thickness (maximum)
(1) + (2) - (0.8 + 0.17) = shim thickness (minimum)
- Add distance (2) (step 5) to distance (1) (step 4).
- 0.8 mm (0.031 inch): Spring washer, a dimension in the installation.
- 0.11 mm (0.004 inch): Minimum thrust clearance.
- 0.17 mm (0.007 inch): Maximum thrust clearance.
(For example)
2.32 + 0.15 - (0.8 + 0.11) = 1.56 mm (0.061 inch)
2.32 + 0.15 - (0.8 + 0.17) = 1.50 mm (0.059 inch)
Take the middle value of the minimum value and the maximum value, and select the 1.53 mm (0.060 inch) shim.
7. Install the 72 mm shim (A) selected and oil guide plate M in the transmission housing (B).
8. Throughly clean the spring washer (A) and washer (B) before installing them on the clutch housing side ball bearing (C). Note the installation direction of the spring washer.
9. Install the mainshaft in the clutch housing.
10. Place the transmission housing over the mainshaft and onto the clutch housing.
11. Tighten the clutch and transmission housings with several 8 mm special bolts (left-hand threads).
NOTE:
- It is not necessary to use sealing agent between the housings.
- The 8 mm special bolts are lefthand thread.
12. Lightly tap on the mainshaft with a plastic hammer.
13. Attach the special tool to the mainshaft as follows:
- Back-out the mainshaft holder bolt (A) and loosen the two hex bolts (B).
- Fit the holder over the mainshaft so its lip is towards the transmission.
- Align the mainshaft holder lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
14. Seat the mainshaft fully by tapping its end with a plastic hammer.
15. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
16. Zero a dial gauge (A) on the end of the mainshaft.
17. Turn the mainshaft holder bolt (B) clockwise; stop turning when the dial gauge (A) has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play.
NOTE: Do not turn the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving. Applying more pressure with the mainshaft holder bolt this may damage the transmission.
18. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the shim thickness.
Standard: 0.11 - 0.17 mm (0.004 - 0.007 inch)