Shim Selection

1. Remove the thrust shim and oil guide plate from the transmission housing. Transmission Housing





2. Install the 3-4 synchro hub, spacer collar, 5th synchro hub, and ball bearing on the mainshaft; install the above assembly in the transmission housing.
3. Measure distance (B) between the end-of the transmission housing and mainshaft.

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

4. Remove the spring washer from the mainshaft.




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

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







6. Select proper shim (or shim pair) from the formula and chart.

NOTE: Do not use more than one shim.

Shim Selection Formula:

From the measurements you made in steps 3 and 5:
1. Add distance C (step 5) to distance B (step 3).
2. From this number, subtract 0.93 (which is midpoint 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.




For Example:
- Try the 1.68 mm shim.

4. Check the thrust clearance in the manner described below.
1. Install the shim selected in the transmission housing.




2. Install the spring washer in the mainshaft.

NOTE:
- Clean the spring and shim thoroughly before installation.
- Install the spring and 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.
6. Tap the mainshaft with a plastic hammer.




7. Attach the collar and shaft holder of the special tool (Mainshaft Thrust Clearance Inspection Tool) to the mainshaft and tighten the three bolts.

CAUTION: Screw the three bolts into the groove below the splines. Never screw into the splined area.




8. Attach the special tool (magnet stand base) to the clutch housing and set the dial gauge on the top of the mainshaft.
9. Turn the bolt clockwise and measure the clearance.

CAUTION:
- Do not turn the bolt more than 60 degrees after the needle of the gauge stops moving. Be careful not to over tighten.
- Measurement should be made at room temperature.

10. Clearance is correct if the reading is between 0.10-0.16 mm (0.0039-0.0063 in.).
If not, recheck necessary shim thickness.