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M/T Clutch Housing Mainshaft Thrust Clearance Adjustment

Special Tools Required

Catch adapter
 07GAJ-PG20110

Base collar
 07GAJ-PG20120

Base adapter
 07GAJ-PG20130

Magnet stand base
 07979-PJ40001
  1. Remove the 52 x 62 mm shim (A) and oil guide plate M from the transmission housing (B).

  1. Thoroughly clean the spring washer (A) and washer (B) before installing them on the ball bearing (C). Note the installation direction of the spring washer.
  1. Install the 3rd/4th synchro hub, the distance collar, the 5th synchro hub, the distance collar, and ball bearing on the mainshaft.
  1. Install the mainshaft in the clutch housing.
  1. Place the transmission housing over the mainshaft and onto the clutch housing.
  1. Secure the clutch and transmission housings with several 8 mm bolts.
    NOTE: It is not necessary to use sealing agent between the housings for this procedure.
  1. Light tap the mainshaft with a plastic hammer.

  1. Attach the special tools to the mainshaft as follows:
    • Back-out the catch adapter bolt (A) and loosen the two hex bolts (B).
    • Fit the holder over the mainshaft so its lip is toward the transmission.
    • Align the catch adapter lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
  1. Seat the mainshaft fully by tapping its end with a plastic hammer.
  1. Thread the catch adapter bolt in until it just contacts the wide surface of the base adapter.

  1. Zero a dial gauge (A) on the end of the mainshaft.
  1. Turn the catch adapter bolt (B) clockwise; stop turning when the dial gauge (A) has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft thrust clearance.
    NOTE: Do not turn the catch adapter bolt more than 60 degrees after the needle of the dial gauge stop moving. Applying more pressure with the catch adapter bolt could damage the transmission.
  1. If the reading is with in the standard, the clearance is correct. If the reading is not within the standards, select the appropriate shim needed from the table, and recheck the thrust clearance.
    Standard:
    0.11−0.18 mm (0.004−0.007 in.)

    (Example)
    Measure reading:
    1.93 mm (0.0759 in.)

    Subtract the middle of the clearance standard 0.14 mm (0.0055 in.) from the total clearance measurement.
    1.93 − 0.14 = 1.79 mm (0.0705 in.)

    Select the shim closest to the amount calculated, for example the 1.78 mm (0.0701 in.) shim.
  1. With oil guide plate M and the appropriate size shim installed in the transmission housing, check the thrust clearance again to verify the clearance is within the standard.

    52 x 62 mm Shim

    Type
    Part Number
    Thickness
    A
    23931-PZ9-000
    0.85 mm (0.0335 in.)
    B
    23932-PZ9-000
    0.88 mm (0.0346 in.)
    C
    23933-PZ9-000
    0.91 mm (0.0358 in.)
    D
    23934-PZ9-000
    0.94 mm (0.0370 in.)
    E
    23935-PZ9-000
    0.97 mm (0.0382 in.)
    F
    23936-PZ9-000
    1.00 mm (0.0394 in.)
    G
    23937-PZ9-000
    1.03 mm (0.0406 in.)
    H
    23938-PZ9-000
    1.06 mm (0.0417 in.)
    I
    23939-PZ9-000
    1.09 mm (0.0429 in.)
    J
    23940-PZ9-000
    1.12 mm (0.0441 in.)
    K
    23941-PZ9-000
    1.15 mm (0.0453 in.)
    L
    23942-PZ9-000
    1.18 mm (0.0465 in.)
    M
    23943-PZ9-000
    1.21 mm (0.0476 in.)
    N
    23944-PZ9-000
    1.24 mm (0.0488 in.)
    O
    23945-PZ9-000
    1.27 mm (0.0500 in.)
    P
    23946-PZ9-000
    1.30 mm (0.0512 in.)
    Q
    23947-PZ9-000
    1.33 mm (0.0524 in.)
    R
    23948-PZ9-000
    1.36 mm (0.0535 in.)
    S
    23949-PZ9-000
    1.39 mm (0.0547 in.)
    T
    23950-PZ9-000
    1.42 mm (0.0559 in.)
    U
    23951-PZ9-000
    1.45 mm (0.0571 in.)
    V
    23952-PZ9-000
    1.48 mm (0.0583 in.)
    W
    23953-PZ9-000
    1.51 mm (0.0594 in.)
    X
    23954-PZ9-000
    1.54 mm (0.0606 in.)
    Y
    23955-PZ9-000
    1.57 mm (0.0618 in.)
    Z
    23956-PZ9-000
    1.60 mm (0.0630 in.)
    AA
    23957-PZ9-000
    1.63 mm (0.0642 in.)
    AB
    23958-PZ9-000
    1.66 mm (0.0654 in.)
    AC
    23959-PZ9-000
    1.69 mm (0.0665 in.)
    AD
    23960-PZ9-000
    1.72 mm (0.0677 in.)
    AE
    23987-PZ9-000
    1.75 mm (0.0689 in.)
    AF
    23988-PZ9-000
    1.78 mm (0.0701 in.)
    AG
    23989-PZ9-000
    1.81 mm (0.0713 in.)
    AH
    23990-PZ9-000
    1.84 mm (0.0724 in.)
    AI
    23991-PZ9-000
    1.87 mm (0.0736 in.)
    AJ
    23992-PZ9-000
    1.90 mm (0.0748 in.)
    AK
    23993-PZ9-000
    1.93 mm (0.0760 in.)
    AL
    23994-PZ9-000
    1.96 mm (0.0772 in.)
    AM
    23995-PZ9-000
    1.99 mm (0.0783 in.)
    AN
    23996-PZ9-000
    2.02 mm (0.0795 in.)
    AO
    23997-PZ9-000
    2.05 mm (0.0807 in.)
    AP
    23998-PZ9-000
    2.08 mm (0.0819 in.)
    AQ
    23999-PZ9-000
    2.11 mm (0.0831 in.)