Mainshaft Thrust Clearance Adjustment
Mainshaft Thrust Clearance AdjustmentSpecial Tools Required
- Mainshaft holder 07GAJ-PG20110
- Mainshaft base 07GAJ-PG20130
NOTE:
- Carry out the measurement at normal room temperature.
- Clean all the parts thoroughly before installation.
1. Remove the 82 mm shim (A) from the transmission housing (B).
2. Install the ball bearing (A), 3rd/4th synchro hub (B), distance collar (C), 5th/6th synchro hub (D), distance collar (E), and angular ball bearing (F) on the mainshaft (G), then install the assembled mainshaft in the transmission housing (H).
NOTE: The angular ball bearing is directional. If installed the wrong way, the measurements will not be accurate.
3. Measure distance (1) between the end of the transmission housing and ball bearing with a straight edge and depth gauge. Measure at three locations, and average the reading.
4. Measure distance (2) the depth of the clutch housing with a straight edge and depth gauge. Measure at three locations, and average the reading.
Shim Selection Formula
5. Select the proper 82 mm shim from the chart. Follow the example, and use the measurements you made in steps 3 and 4.
(Basic Formula)
(2) - (1) (0.85 + 0.14) = shim thickness (maximum)
(2) - (1) (0.85 + 0.21) = shim thickness (minimum)
- Subtract distance (2) (step 4) from distance (1) (step 3).
- 0.85 mm (0.033 inch): Spring washer, a dimension in the installation.
- 0.14 mm (0.006 inch): Minimum thrust clearance.
- 0.21 mm (0.008 inch): Maximum thrust clearance.
(For example)
21.04 - 17.97 - (0.85 + 0.14) = 2.08 mm (0.082 inch)
21.04 - 17.97 - (0.85 + 0.21) = 2.01 mm (0.079 inch)
Take the middle value 2.04 mm (0.080 inch) of the minimum value and the maximum value, and select the 0.93 mm (0.037 inch) and 1.11 mm (0.044 inch) shims.
NOTE: Enable to select the two sizes of 82 mm shim.
6. Install the selected 82 mm shim (A) in the transmission housing (B).
7. Throughly clean the spring washer (A) before installing it on the clutch housing (B). Note the installation direction of the spring washer.
8. Install the mainshaft in the clutch housing.
9. Place the transmission housing over the mainshaft and onto the clutch housing.
10. Tighten the clutch and transmission housings with several 10 mm bolts.
NOTE: It is not necessary to use sealing agent between the housings.
11. Lightly tap on the mainshaft with a plastic hammer.
12. 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 splices, then tighten the hex bolts.
13. Seat the mainshaft fully by tapping on its end with a plastic hammer.
14. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
15. Zero a dial gauge (A) on the end of the mainshaft.
16. Turn the mainshaft holder bolt (B) clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play. Do not turn the mainshaft holder bolt more than 60° after the needle of the dial gauge stops moving. Applying more pressure with the mainshaft holder bolt may damage the transmission.
17. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the shim thickness.
Standard: 0.14 - 0.21 mm (0.006 - 0.008 inch)