2. Install the 3rd/4th synchro hub, spacer, 5th synchro hub, bush, and ball bearing onto the output shaft, then install these assemblies into the transaxle case.
3. Install the washer on the output shaft.
4. Measure the distance (A) between the end face of the gearbox housing and the washer.
Note:
- Use a ruler and caliper.
- Take a measurement at three locations and average these values.
5. Measure the distance (IN) between the end face of the clutch housing and the inner ring of the bearing.
Note:
- Use a ruler and caliper.
- Take a measurement at three locations and average these values.
6. Select the required 78mm shim from the table using the following formula.
Puck selection formula
From the measurements performed in paragraphs. 4 and 5:
- 1. Add distance (IN) (item 5) to distance (A) (item 4).
- 2. Subtract 0.93 from this number (which is the mid-point of bending of the spring washer of the clutch housing bearing.
- 3. Take this number and compare it with the available washer sizes in the table.
FOR EXAMPLE:
Try a 1.68mm washer.
Adjusting washer 78 mm
catalog no | Thickness | |
A | 23941-Р16-000 | 1.20 mm |
IN | 23942-Р16-000 | 1.23mm |
WITH | 23943-Р16-000 | 1.26mm |
D | 23944-Р16-000 | 1.29 mm |
E | 23945-Р16-000 | 1.32mm |
F | 23946-Р16-000 | 1.35mm |
G | 23947-Р16-000 | 1.38mm |
H | 23948-Р16-000 | 1.41 mm |
I | 23949-Р16-000 | 1.44mm |
J | 23950-Р16-000 | 1.47 mm |
TO | 23951-Р16-000 | 1.50 mm |
L | 23952-Р16-000 | 1.53 mm |
M | 23953-Р16-000 | 1.56mm |
N | 23954-Р16-000 | 1.59 mm |
ABOUT | 23955-Р16-000 | 1.62 mm |
R | 23956-Р16-000 | 1.65 mm |
Q | 23957-Р16-000 | 1.68mm |
R | 23958-Р16-000 | 1.71 mm |
S | 23959-Р16-000 | 1.74mm |
T | 23960-Р16-000 | 1.77mm |
And | 23961-Р16-000 | 1.80 mm |
V | 23962-Р16-000 | 1.83 mm |
W | 23963-Р16-000 | 1.86 mm |
X | 23964-Р16-000 | 1.89 mm |
At | 23965-Р16-000 | 1.92 mm |
Z | 23966-Р16-000 | 1.95 mm |
AA | 23967-Р16-000 | 1.98 mm |
AB | 23968-Р16-000 | 2.01mm |
AC | 23969-Р16-000 | 2.04mm |
AD | 23970-Р16-000 | 2.07 mm |
AE | 23971-Р16-000 | 2.10 mm |
F | 23972-Р16-000 | 2.13mm |
AG | 23973-Р15-000 | 2.16mm |
AN | 23974-Р16-000 | 2.19 mm |
AI | 23975-Р16-000 | 2.22mm |
AJ | 23976-Р16-000 | 2.25mm |
AK | 23977-Р16-000 | 2.28 mm |
AL | 23978-Р16-000 | 2.31mm |
AM | 23979-Р16-000 | 2.34mm |
AN | 23980-Р16-000 | 2.37mm |
7. Check the thrust clearance as follows:
Note: The measurement should be carried out at normal room temperature.
1. Install a matched 78mm washer and oil distributor plate into the transmission case.
2. Install the spring washer and washer on the ball bearing.
Note:
- Thoroughly clean the spring washer, washer and thrust washer before installation.
- Install the spring washer, washer and thrust washer correctly.
3. Install the output shaft in the clutch housing.
4. Place the gearbox housing on the output shaft and on the clutch housing.
5. Pull together the gearbox and clutch housings with several 8mm bolts.
Note: It is not necessary to apply sealant between the crankcases.
6. Tap the output shaft with a plastic mallet.
7. Slide the output shaft base onto the output shaft.
8. Attach the output shaft retainer to the output shaft as follows:
Note:
- Loosen the output shaft retainer bolt and loosen the two hex bolts.
- Slide the retainer onto the output shaft so that its edge is facing the gearbox.
- Align the lip of the output shaft retainer with the groove on the inner spline of the output shaft, then tighten the hex bolts.
9. Fully seat the output shaft by tapping on its end with a plastic hammer.
10. Screw in the pinion shaft retainer bolt until it just touches the wide area of the pinion shaft base.
11. Set the indicator to zero by resting its head against the end of the output shaft.
12. Turn the output shaft retainer bolt clockwise, stop turning when the indicator reaches the end of its travel. The indication of the indicator is the axial play of the secondary shaft.
Warning! If you continue to turn the output shaft lock bolt more than 60 degrees after the indicator needle stops moving, the transmission may be damaged.
13. If the readings are within acceptable limits, the gap is normal.
If the reading is out of specification, recheck the thickness of the shim.
- Standard: 0.11-0.18mm