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 28 mm washer (H) on the mainshaft.
4. Measure the distance (1) between the end of the transmission housing and 28 mm washer with a straight edge and vernier caliper. Measure at three locations, and average the reading.
5. Measure the 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 below, 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 in.): Spring washer, a dimension in the installation.
^ 0.11 mm (0.004 in.): Minimum thrust clearance.
^ 0.17 mm (0.007 in.): Maximum thrust clearance.
(For example)
2.32 + 0.15 - (0.8 + 0.11) = 1.56 mm (0.061 in.)
2.32 + 0.15 - (0.8 + 0.17) = 1.50 mm (0.059 in.)
Take the middle value of the minimum value and the maximum value, and select the 1.53 mm (0.060 in.) shim.
7. Install the 72 mm shim (A) selected and oil guide plate M in the transmission housing (B).
8. Thoroughly clean the 28 mm spring washer (A) and 28 mm washer (B) before installing them on the clutch housing side ball bearing (C).
NOTE: Install the spring washer in the direction shown.
9. Install the assembled mainshaft in the clutch housing.
10. Place the transmission housing over the mainshaft and into 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 have left-hand threads.
12. Lightly tap on the mainshaft with a plastic hammer.
13. Attach the mainshaft base (A) and mainshaft holder (B) to the mainshaft as follows:
^ Back-out the mainshaft holder bolt (C), and loosen the two hex bolts (D).
^ 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. Fully seat the mainshaft by tapping its end with a plastic hammer.
15. Thread in the mainshaft holder bolt 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, and 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 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 in.)