Mainshaft Thrust Shim

1. Remove the 78 mm shim and oil guide plate from the transmission housing.




2. Install the 3rd/4th synchro hub, spacer collars 5th synchro hub, and ball bearing on the mainshaft then install the above assembly in the transmission housing.
3. Install the washer on the mainshaft.
4. Measure distance (B) between the end of the transmission housing and washer.

NOTE:
- Use a straight edge and vernier caliper.
- Measure at three locations and average the reading.




5. Measure distance (C) between the end of the clutch housing and bearing inner race.

NOTE:
- Use a straight edge and depth gauge.
- Measure at three locations and average the readings.

6. Select the proper 78 mm shim from the chart by using the formula below.

NOTE: Use only one 78 mm shim.

Shim Selection Formula:

From the measurements you made in steps 4 and 5:
1. Add distance (C) (step 5) to distance (B) (step 4).
2. From this number, subtract 0.93 (which is the midpoint of the flex range of the clutch housing bearing spring washer).
3. Take this number and compare it to the available shim sizes in the chart.







- Try the 1.68 mm (0.0661 in) shim.

7. Check the thrust clearance in the manner described below.

NOTE: Measurement should be made at normal room temperature.




1. Install the 78 mm shim selected and oil guide plate in the transmission housing.




2. Install the spring washer and washer on the ball bearing.

NOTE:
- Clean the spring washer, washer and thrust shim throughly before installation.
- Install the spring washer, washer and thrust shim properly.




3. Install the mainshaft in the clutch housing.
4. Place the transmission housing over the mainshaft and onto the clutch housing.
5. Tighten the clutch and transmission housings with several 8 mm and 10 mm bolts.

NOTE: It is not necessary to use sealing agent between the housings.

6. Tap the mainshaft with a plastic hammer.
7. Slide the mainshaft base over the mainshaft.




8. Attach the mainshaft holder to the mainshaft as follows:

NOTE:
- Back-out the mainshaft holder bolt and loosen the two hex bolts.
- 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, then tighten the hex bolts.

9. Seat the mainshaft fully by tapping its end with a plastic hammer.
10. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.




11. Zero a dial gauge on the end of the mainshaft.
12. Turn the mainshaft holder bolt 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.

CAUTION: Turning the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving may damage the transmission.

13. If the reading is within the standard, the clearance is correct.
If the reading is not within the standard, recheck the shim thickness.

Standard: 0.10-0.16 mm (0.004-0.006 in)