intermediate shaft end play on 2.0
 

I was looking at an early 2.0 today. A friend was checking the intermediate shaft end play by puching the gear back and forth. The movement was slight but evident. Things changed quit a bit when he put a socket on the crank and turned it in the direc. of rotation. The intermediate shaft moved outward quite a bit more. If you move the crank back a bit and then forward, the shaft actually clunks at the end of it's travel. I asked about backlash and he said it was within tolerance. Any ideas why this is happening? Thanks in advance for any help!

early 2.0 end play
 

I have heard that in the past, it has too much clearence, the proper range is .0031-.0047 in. which will not make much noise changing directions on the crank, it needs to be correct
Mike Bruns JBRacing.com

Jon,
Since the intermediate gear and the drive gear on the crankshaft are cut at an angle, the intermediate gear moves laterally when driven.
Since the motor only turns clockwise, driving the intermediate gear counter-clockwise, the intermediate gear will normally run in the position you find it in when turning the crank shaft clockwise.
It does not move back and forth, since the motor only runs clockwise.

Mike, & Doug, Thanks for the replys.

There's a procedure for setting this end play in the Rebuild Book...

-Wayne

Thanks Wayne. The static condition disscussed in your book is not the issue here.

Since the end play in early 2.0 engine is determined by the end cap (steel in early engines) if you are checking it with the end cap off it will have a great deal of play.

Unlike later engines there is no thrust bearing on the shaft.
Pull the end cap, set the play as per Wanye's book (I assume it's correct, I haven't read it) and check to see if the the clunk has gone away.

Thank you Henry. We tried this method. When the end-pllay is checked statically, as in Wayne's book, and then set, the shaft runs into the cover under load.

That is how it is designed.
The cover sets the end play. Not a great design but it is what it is.
When using these cases for race engines we generally machine the case to except late style thrust bearings and install a later intermediate shaft. The corresponding aluminum cover is then used.
Before you check the end play, make sure there are no rough edges on the end of the shaft and that the plate is flat.
Remember that this early cover requires a special gasket and shims that are not included the most gasket sets.

Got it. Thanks Henry.