Mainshaft: Adjustments

Mainshaft Thrust Clearance Adjustment

Special 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 ball bearing (F) on the mainshaft (G), then install the assembled mainshaft in the transmission housing (H).
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.




5. Select the proper 82 mm shim from the chart. Follow the example, and use the measurements you made in Step 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) to distance (1) (step 3).
- 0.85 mm (0.33 in): spring washer, a dimension in the installation.
- 0.14 mm (0.006 in): minimum thrust clearance
- 0.21 mm (0.008 in): maximum thrust clearance


For example
21.04 - 17.97 - (0.85 + 0.14) = 2.08 mm (0.082 in)
21.04 - 17.97 - (0.85 + 0.21) = 2.01 mm (0.079 in)

Take the middle value 2.04 mm (0.080 in) of the minimum value and the maximum value, and select the 0.93 mm (0.037 in) and 1.11 mm (0.044 in) shims.

NOTE: Enable to select the two sizes of 82 mm shim.




6. Install the 82 mm shim (A) selected the transmission housing (B).
7. Thoroughly 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's lip around the groove at the inside of the mainshaft splines.
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 ply. 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.
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 in)