151
Front Section Assembly
4
FSO-2405 2nd Ed. 02/07 Front Section
FSO-2405/28
27
End Play Adjustment
Example #1: countershaft end play adjustment
Specified end play: 0,010 mm to 0,080 mm
Measured end play: 0,47 mm
As the measured value is greater than 0,080 mm (maximum specified), calculate:
0,470 – 0,080 = 0,390 mm (R1)
0,470 – 0,010 = 0,460 mm (R2)
The shim pack thickness must be within 0,390 mm and 0,460 mm.
Example #2: mainshaft end play adjustment
Specified end play: 0,010 mm to 0,060 mm
Measured end play: 0,15 mm
As the measured value is greater than 0,060 mm (maximum specified), calculate:
0,150 – 0,060 = 0,090 mm (R1)
0,150 – 0,010 = 0,140 mm (R2)
The shim pack thickness must be within 0,090 mm and 0,140 mm.
Example #3: countershaft end play adjustment
Specified end play: 0,010 mm to 0,080 mm
Measured end play: 0,005 mm
In this case, it is not possible to calculate the shim thickness, since the clearance is
already less than the minimum specified. This measured value is not a valid value.
So, it is necessary to redo the measurement, verifying before if all existing shims were
actually removed, if the bearing cup is perfectly seated on the bearing bore and free
of any kind of dirt, and if the shaft is seated properly on the bearing, by rotating the
shaft in both directions clockwise and counterclockwise.
27. Shift the 1st gear and remove the retaining roll
pin from the shift lug, by pushing it forward into
the housing.
NOTE: Use a 6 mm diameter pin punch.
28. Remove the retaining capscrews from the
intermediate housing.
29. Remove the intermediate housing.
NOTE: If necessary, carefully hit the
housing’s capscrews area with a plastic
hammer to detach the housing.
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