Got my Case all cleaned and stripped. Got my Jacks internals ready to go. All thats left is to get the proper Shims.
My question is whats the best way to get the measurements needed to get the proper shims? Whats people using?
I do have the specs.
My guess is to bolt the case together with the shafts,bearings and races in place. use some kind of clay or specal plastic guage between the bearing race and case (put this where the shims would normally go). Then pull the case back apart, remove the bearing race and measure the thickness. And use that measurement to decide what shim is needed?
This is the only way I can think to do it. Im in Nova Scotia and theres noone here that knows this. So its time I figure it out.
Thanks for any help.

This will help I think!
http://www.ca.dsm.org/forums/ubbthreads.php?ubb=showflat&Board=12&Number=270220

Ahhh... I never thought of solder... Thats great.
Thanks Rob.

At least you thought of something, I would have just stared at it and scratched my head I just remembered reading that thread way back when

Use 2-3 pieces of rosin core solder with a little grease or vaseline on it to hold it in place per race. Torque case to 30 ft lbs, remove everything and measure thickness.

Sounds like you were asking the wrong Nova Scotias... I've done this many times.

One other tip... Before tossing the trans back in the car, be sure to bench test it (i.e. run it through all the gears). You don't want to find out there's a problem after you've spent all that time bolting the car back together. Been there.

ok, heres how I made out.
I used .060" resin core solder.
The case is stripped. I did each shaft 1 at a time.
And I used specs supplied by Ghislain.
I will have close to 600 TQ and use the transmission on the Street/Strip.
Heres my measurements, specs and shims needed.
-Input Shaft
Measures .0525
Specs .005-.007
Shim needed .0475-.0455
-Int Shaft
Measures .0430
Specs .007-.009
Shim needed .036-.034
-Center diff
measures .0515
specs .005-.007
Shims needed .0465-.0445
-output shaft
measures .0580
specs .003-.005
shims needed .0550-.0530
-Front diff
measures .0420
specs .002-.0067
shim needed .040-.0353

I put my results here for any suggestions. Make sure everyone who knows agrees.
Thanks

Here's Tim Zimmer's recommended specs: http://www.dsmlink.com/forums/showpost.php?p=492103&postcount=5

All of your numbers show a clearance. SOme should be 0 or with a preload. I believe input shaft is supposed to be preloaded and intermediate bascially 0 clearance (depending on how tight you want to go some people will preload both). Can't remember the rest off hand.

Those are the Specs that I passed on to Troy.

IIRC I got them on ECMLink forums as few years ago;

Tranny Shim Specs

The following is for W5M33 AWD 5-speed DSM transmissions:

Ok, stock specs are:

The Preload Setting is listed in SAE (inches):

Input Shaft --> 0.000" - 0.002" ENDPLAY
Intermediate Shaft --> 0.003" - 0.005" PRELOAD
Center Differential --> 0.003" - 0.005" PRELOAD
Output Shaft --> 0.003" - 0.005" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

These are what I normally use:

Stock/Street Transmissions with less than 400TQ at the crank:

Input Shaft --> 0.004" - 0.007" PRELOAD
Intermediate Shaft --> 0.005" - 0.007" PRELOAD
Center Differential --> 0.005" - 0.007" PRELOAD
Output Shaft --> 0.003" - 0.005" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

Street/Strip Transmissions with less than 600TQ at the crank:

Input Shaft --> 0.005" - 0.007" PRELOAD
Intermediate Shaft --> 0.007" - 0.009" PRELOAD
Center Differential --> 0.005" - 0.007" PRELOAD
Output Shaft --> 0.003" - 0.005" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

All out RACE Transmissions that are Rebuilt/Inspected regularly with more than 600TQ at the crank:

Input Shaft --> 0.007" PRELOAD
Intermediate Shaft --> 0.008" - 0.010" PRELOAD
Center Differential --> 0.005" - 0.007" PRELOAD
Output Shaft --> 0.004" - 0.006" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

For Extremely HIGH HP/TQ transmissions (As in ~900-1000+TQ at the crank):

Input Shaft --> 0.007" PRELOAD
Intermediate Shaft --> 0.010" - 0.012" PRELOAD
Center Differential --> 0.005" - 0.007" PRELOAD
Output Shaft --> 0.004" - 0.006" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

I usually preload everything except the front diff on all rebuilds that I have done. The tighter preloads makes shifting up top smooth and crisp.

Wow... Its a good thing I re read this. I took it as all clearance. Rather then preload.
I have not put it together yet. Well completley anyways. Better get the right shims

Its all together now. Everything is on the tight side of within specs. Im going to install it along with my PTT twin disk and new Isuzu Slave.
But it seems to be a bit tight. I can shift it through all gears and I can turn the input shaft with my hands. But Just barely. I have assembeled lots of trannys. But this is the first with jacks internals and the first that I have shimmed. All the rest I just reused the stock shims.
Im hoping it just needs to be run and set in.
I guess we will find out.

I know NOTHING about rebuilding transmissions, but in over 40 years as a tool & die maker, I DID learn a little bit about machinery in general. Some of those numbers surprise me a little. PRELOAD of over .004 sure SOUNDS like a lot. It would surprise me that you can still turn the input shaft by hand if some of the internals are shimmed that tight...

Well, Its all in and running now. It shifts great. Im still super nervous about how tight everything is. And over pressing the PTT pressure plate. it took more more time setting that up then anything.
But it sounds great. Shifts amazing

Going to resurrect this cause it's been great reference (Ghis' post being the big one) and also add this post from tooners that has some great info too.
http://www.dsmtuners.com/threads/setting-bearing-preloads.442999/

many many years on and the 400tq version is still going strong for me!