( TL19E1AE34150439755MBAT00 )

M/T Clutch Housing Mainshaft Thrust Clearance Adjustment

Special Tools Required
Catch adapter
07GAJ-PG20110
Base adapter
07GAJ-PG20130

1. Remove the 72 mm shim (A) and oil guide plate M from the transmission housing (B).

1. Thoroughly clean the 28 mm spring washer (A) and the 28 mm washer (B) before installing them on the clutch housing side ball bearing (C). Note the installation direction of the spring washer.

1. Assemble the all of mainshaft components correctly: R20A3 engine model, K24Z3 engine model.

1. Install the mainshaft assembly in the clutch housing.

1. Place the transmission housing over the mainshaft and onto the clutch housing.

1. Tighten the clutch and transmission housings with several 8 mm bolts.
   NOTE: It is not necessary to use sealing agent between the housing for this procedure.

1. Lightly tap on the mainshaft with a plastic hammer.

1. Attach the catch adapter (A) and base adapter (B) to the mainshaft as follows:
   - Back out the catch adapter bolt (C), and loosen the two hex bolts (D).
   - Fit the holder over the mainshaft so its lip is towards the transmission.
   - Align the catch adapter lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.

1. Fully seat the mainshaft 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 mainshaft holder bolt (B) clockwise; stop turning when the dial gauge 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 stops 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 standard, select the appropriate shim needed from the table, and recheck the thrust clearance.

   Standard: | 0.11−0.17 mm (0.004−0.007 in.)

   (Example)
   Measure reading: | 1.93 mm (0.076 in.)

   Subtract the total clearance measurement from the middle of the clearance standard 0.14 mm (0.0056 in.).

   1.93 − 0.14 (0.076 − 0.006) = 1.79 mm (0.070 in.)

   Select the shim closest to the amount calculated, for example the 1.80 mm (0.071 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.
   72 mm Shim

   Type | Part Number | Thickness
   --- | --- | ---
   A | 23931-P21-000 | 0.60 mm (0.024 in.)
   B | 23932-P21-000 | 0.63 mm (0.025 in.)
   C | 23933-P21-000 | 0.66 mm (0.026 in.)
   D | 23934-P21-000 | 0.69 mm (0.027 in.)
   E | 23935-P21-000 | 0.72 mm (0.028 in.)
   F | 23936-P21-000 | 0.75 mm (0.030 in.)
   G | 23937-P21-000 | 0.78 mm (0.031 in.)
   H | 23938-P21-000 | 0.81 mm (0.032 in.)
   I | 23939-P21-000 | 0.84 mm (0.033 in.)
   J | 23940-P21-000 | 0.87 mm (0.034 in.)
   K | 23941-P21-000 | 0.90 mm (0.035 in.)
   L | 23942-P21-000 | 0.93 mm (0.037 in.)
   M | 23943-P21-000 | 0.96 mm (0.038 in.)
   N | 23944-P21-000 | 0.99 mm (0.039 in.)
   O | 23945-P21-000 | 1.02 mm (0.040 in.)
   P | 23946-P21-000 | 1.05 mm (0.041 in.)
   Q | 23947-P21-000 | 1.08 mm (0.043 in.)
   R | 23948-P21-000 | 1.11 mm (0.044 in.)
   S | 23949-P21-000 | 1.14 mm (0.045 in.)
   T | 23950-P21-000 | 1.17 mm (0.046 in.)
   U | 23951-P21-000 | 1.20 mm (0.047 in.)
   V | 23952-P21-000 | 1.23 mm (0.048 in.)
   W | 23953-P21-000 | 1.26 mm (0.050 in.)
   X | 23954-P21-000 | 1.29 mm (0.051 in.)
   Y | 23955-P21-000 | 1.32 mm (0.052 in.)
   Z | 23956-P21-000 | 1.35 mm (0.053 in.)

   72 mm Shim

   Type | Part Number | Thickness
   --- | --- | ---
   AA | 23957-P21-000 | 1.38 mm (0.054 in.)
   AB | 23958-P21-000 | 1.41 mm (0.056 in.)
   AC | 23959-P21-000 | 1.44 mm (0.057 in.)
   AD | 23960-P21-000 | 1.47 mm (0.058 in.)
   AE | 23961-P21-000 | 1.50 mm (0.059 in.)
   AF | 23962-P21-000 | 1.53 mm (0.060 in.)
   AG | 23963-P21-000 | 1.56 mm (0.061 in.)
   AH | 23964-P21-000 | 1.59 mm (0.063 in.)
   AI | 23965-P21-000 | 1.62 mm (0.064 in.)
   AJ | 23966-P21-000 | 1.65 mm (0.065 in.)
   AK | 23967-P21-000 | 1.68 mm (0.066 in.)
   AL | 23968-P21-000 | 1.71 mm (0.067 in.)
   AM | 23969-P21-000 | 1.74 mm (0.069 in.)
   AN | 23970-P21-000 | 1.77 mm (0.070 in.)
   AO | 23971-P21-000 | 1.80 mm (0.071 in.)
   AP | 23972-PPP-J00 | 1.83 mm (0.072 in.)
   AQ | 23973-PPP-J00 | 1.86 mm (0.073 in.)
   AR | 23974-PPP-J00 | 1.89 mm (0.074 in.)
   AS | 23975-PPP-J00 | 1.92 mm (0.076 in.)
   AT | 23976-PPP-J00 | 1.95 mm (0.077 in.)
   AV | 23977-PPP-J00 | 1.98 mm (0.078 in.)
   AW | 23978-PPP-J00 | 2.01 mm (0.079 in.)
   AX | 23979-PPP-J00 | 2.04 mm (0.080 in.)
   AY | 23980-PPP-J00 | 2.07 mm (0.081 in.)
   AZ | 23981-PPP-J00 | 2.10 mm (0.083 in.)
   BA | 23982-PPP-J00 | 2.13 mm (0.084 in.)
   BB | 23983-PPP-J00 | 2.16 mm (0.085 in.)
   BC | 23984-PPP-J00 | 2.19 mm (0.086 in.)
   BD | 23985-PPP-J00 | 2.22 mm (0.087 in.)
   BE | 23986-PPP-J00 | 2.25 mm (0.089 in.)