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Intermediate shaft backlash problem
During my enging rebuild, I noticed that the intermediate shaft gear was worn so I replaced it. It was a "0" (identifying number) gear and I replaced it with a "0" gear. Upon reassembly, I measured the backlash at about .07 mm. the upper limit in the PP rebuild book and the factory manual .049 mm. The crank gear does not look worn at all, and it seems hard to believe that the aluminum I-shaft gear could cause wear on the steel crank gear. Any opinions on this ? I am really having a hard time deciding what to do here. I can replace the "0" crank gear with a new "0" gear but I am afraid I will still have the same backlash problem (FYI the gear is $275). I also noticed that in the factory manual certain combinations of gears are permissable for my "0" block (Sec. 38EN page E93). One possible combination is a "0" crankshaft gear and a "1" intermediate shaft gear. Based on page 93a, it appears that the "1" I-shaft gear is .05 mm larger than the "0" I-shaft gear. Is this an acceptable method of reducing my backlash ? Any help on this would be greatly appreciated.
Thanks,
Dave
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