Manual Transmission/Transaxle: Adjustments

ADJUSTMENTS
MAIN SHAFT BEARINGS





1. Install input shaft in to front adapter (Fig. 91).
2. Install main shaft and bearing.
3. Install case and bolt together using all bolts.





4. Install 5-6 driven gear (Fig. 92).

NOTE: All measurements will be taken from this near.

5. Rotate the input shaft and main shaft back and forth to seat bearings.
6. Set up dial indicator on the end of the input shaft.
7. Zero the dial indicator and then push up on the input shaft. Record the end play reading obtained. If there is no end play recorded, a thinner shim must be installed behind the bearing cone in the front adapter. Install 0.010 inch thinner shims until an end play reading can be read.
8. Once an end play reading is obtained, add 0.002 inch to the reading recorded in Step 7.
9. Add the number obtained in Step 8 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
10. Install a shim(s) behind the bearing cone in the front adapter equal to the number recorded in Step 9.

CLUSTER GEAR BEARINGS
1. Remove inspection plug in the front adapter.





2. Place cluster gear into front adapter (Fig. 93).





3. Install case onto front adapter and tighten all adapter bolts (Fig. 94).
4. Place cluster extension into back of transmission.





5. Install special tool 6625 into front of transmission and hand tighten (Fig. 95).
6. Stand transmission on end. The adapter should point upward.





7. Set up dial indicator as shown in (Fig. 96).
8. Zero the dial indicator and then push on the cluster gear shaft. Record the end play reading obtained. If here is no end play recorded, a thinner shim must be installed behind the bearing cone in the front adapter. Install 0.010 inch thinner shim until an end play reading can be read.
9. Once an end play reading is obtained, add 0.002 inch to the reading recorded in Step 8.
10. Add the number obtained in Step 9 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
11. Install a shim(s) behind the bearing cone in the front adapter equal to the number recorded in Step 10.

COUNTER SHAFT EXTENSION END PLAY
1. Assemble tail housing with original shim.





2. Install special tool 6625 (Fig. 97). Snug down tool and then loosen two turns.





3. Install dial indicator (Fig. 98).
4. Zero the dial indicator and record the end play reading. If there is no end play recorded, a thinner shim must be installed. Install .010 in. thinner shim until an end play reading can be obtained.
5. Once an end play reading has been obtained. Then add the number obtained in Step 4 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
6. Install a shim(s) behind the bearing cone in the extension housing equal to the number recorded in Step 5.