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Originally Posted by keithmac
That seems to be the internal gear backlash measurement, spec states 0.1 to 0.16mm as acceptable?. Have you trad though the sdjustment part of the manual?
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What and where is the output shaft adjustment procedure in the manual?
The specs the dealer quoted me was 0 - 0.004 inches which works out to 0 - 0.1016 mm measured at the output shaft.
They said they measured, with a dial indicator, 0.0015 inches which works out to ~ 0.04 mm. These measurements don't add up because I personally measured ~ 2 mm of backlash, using a pair of calipers, caused by the VCU & Planetary dowel pins. Like Kormex said, I should throw the dealer measurements out the window and start from scratch.
I took my car out for a spin today to see if I could give a better description of the clunk so that I can try and figure out where its coming from. The clunk exists in 1st gear, but I would characterize it as very minimal to non-existent. Once I shift into 2nd, it starts to become more noticeable and it gets worse in 3rd, even worse in 4th and its brutal in 5th. I don't know if this information helps.
Edit: I just got back from another drive and yes it does do it just as bad in 1st. If I get on it hard enough in any gear it will do it, it just seems to do it easier in the higher gears. I find this a bit strange, because wouldn't there be more torque in the lower gears?
I'm hoping to get under the car this weekend and I'll report back with some better measurements.
Declan