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Old 09-01-2013, 08:48 AM
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Stretch Stretch is offline
...like a shield of steel
 
Join Date: Sep 2009
Location: Somewhere in the Netherlands
Posts: 14,461
Certain things you might want to check (1)

=> Please note <= I'm not taking those pesky shafts down to component parts. There are checks to be done on the synchro parts - there are wear limits that should be checked. Like I said I'm not bothering - I'm taking a gamble - I reckon I got a diamond here. It'll be alright - it'll do a trip!

{This could bite me on the arse of course}

So assuming you've checked and re-assembled the lay shaft and the main shaft and it is all good...

...it is worthwhile making a few measurements to make sure that the bearing clearances are good.

The first thing that can be done is to check that the main shaft is at the correct height with respect to the intermediate plate.

Looking back at the specifications listed above it should be 138.4 mm



Spin the main shaft around on its taper roller bearing whilst it sits in the intermediate plate cup. Try making measurements at several points on the casting. Ideally you need a bigger foot on a depth gauge than the one I have.

This dimension is adjusted by changing the shims under the bearing cup in the intermediate plate.



Note that the bearing cup for the lay shaft has NO shims!
Attached Thumbnails
717.412 (5 speed manual gearbox) refresh-717_412-measure-distance-intermediate-plate-3-4-syncro-body.jpg  
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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!
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