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Transmission and Transfer Case Shim Lists for DSM / Evo 1-3, GVR4, RVR, Chariot, etc.

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I am asked many times for help with selecting shims for the DSM W5Mxx and F5Mxx transmissions and transfer cases. I figured this would be much more helpful for you all to work with.

Just understand that many of these are obsolete parts nowadays. Either way, these lists are here to make your life easier to select the correct shim and associated part number for your build.

On a side note, people have already re-posted my transmission bearing preload specs I would use for helical gearsets for many, many years now, but some quick notes below for transfer case and PPG dogbox setups. If you look at the helical vs straight cut gearsets, I TYPICALLY set the straight cut gearsets up with a bit less bearing preload as they are more stable under load than a helical gearset. It is imperative to have all of your case, shift rail detent and 5th gear cover limiters and gearset clearances checked and completed when using a PPG gearset before final assembly.

DSM TRANSFER CASES
DSM TRANSFER CASE SHIM SELECTION AND SETUP NOTES
Mid Housing Pinion Bearing Preload --> 0.002-0.003" PRELOAD
It should smoothly turn the bearing in the press with a little drag but no binding, or with shaft nut torqued to 100ft/lbs when rotating the shaft vs mid housing. The pinion spacer sleeve should be measured and noted, typically it is between 2.611-2.614".
*NOTE: When setting up the transfer case, it is easiest to set up having the tailshaft splined portion clamped down in a bench vise with aluminum or Nylon/ Delrin soft jaws facing upwards. The pinion shaft should be already mounted in the mid housing with its bearings, spacer sleeve and pinion bearing shim selected, with the shaft nut installed and torqued to 100ft/lb before starting your shimming process. DO NOT STAKE THE SHAFT NUT YET. This way, you can easily place the mid housing spacer and mount the front housing for doing shim adjustment. ***Please note that when using the Magnus billet front housing WITH a Brena / Magnus gearset, you will need to install the input sleeve and drive gear into the front housing first with the side cover before placing on the mid housing. Also be aware that the pocket depth of the Magnus billet side cover may need additional machinework so that the drive gear outer bearing doesn't bind into the cover as it typically requires a very thin shim. If your side cover shim is thinner than approx. 0.045", you will require the pocket to be machined deeper. It is also useful to machine the side cover with a square o-ring groove to match the OEM side cover pocket depth and groove dimension.
Mid Housing Spacer Shim Selection
The mid housing spacer plate shim is imperative to select first to get your pattern placement, and then, continue on to get your proper backlash and side cover bearing preload. It is a back and forth process. Typically with a stock gearset, or liberty modified tailshaft stock gearset, start around the 0.010-0.012" range for the mid housing shim and adjust up / down from there. With the Magnus / Brena billet gearset, the pattern can be difficult to set up and is very inconsistent from batch to batch. It can be anywhere from -0.008" to + 0.020" so custom shims may be needed to space the drive gear on the input sleeve towards the side cover as well as a custom shim made to go under the driven gear on the shaft and the inner pinion bearing to raise up the gear height and use a thicker shim for the mid housing.
Inner Drive Gear Backlash --> 0.0035-0.0065" BACKLASH
Start with a thicker side cover shim that will have excessive bearing preload or use 3/32" solder to find the zero value correlation vs the backlash shim to adjust in thickness as you adjust the backlash shim to get your correct value. Be sure to have 0.002-0.003" bearing preload on the side cover shim once your backlash shim has been correctly selected, and your pattern is perfectly centered. You will adjust pattern placement with your mid housing spacer plate shims and will need to get the pattern correct first before finalizing your backlash and side cover preload.
Outer Drive Gear Side Cover Bearing Preload --> 0.002-0.004" PRELOAD
Once you have a bearing backlash shim installed and have done the solder crush method test to find your side cover bearing zero value, select a thicker shim to add preload. Install the side cover shim, install side cover and torque to spec, and test turning feel. Adjust if necessary. Use a magnetic base dial indicator mounted on your bench vise to check backlash in between adjustments to the backlash shim and the side cover preload shim to confirm your measurements.
Torque Spec Notes:
Mid Housing Bolts - 29 ft/lb, star pattern, torqued evenly. You can set it up using a cordless 3/8" impact with a 14mm swivel socket and 3" extension for fast assembly and disassembly. Be sure to note that you will need shallower head bolts for the two top mounting locations when using a Boostin billet mid housing. The three lower bolts can be a standard JIS flange bolt. Also note to check your thread depths and tap further if necessary if you are using a Magnus billet front housing, as they can sometimes not be tapped fully with a M10x1.25 bottoming tap. USE TAP OIL. Typically the bolts used will be M10x1.25x 25mm or 30mm length depending on application.
*NOTE: If using a Boostin billet mid housing, you may want to use a bit of RTV sealant on the OD bore of the mid housing after installing your O-ring, so that you do not have a leakage issue. If you are using a Magnus billet front housing, you will definitely want to use RTV on both the side cover OD and the mid housing OD bore when doing final assembly.
Side Cover Bolts - 29 ft/lb, star pattern, torqued evenly. You can set up with a 3/8" impact with a 14mm socket for fast assembly and disassembly. If you are still working with setting up bearing preload and are dealing with bearing binding while rotating, use a 3/8" ratchet with 14mm deep socket to finely tighten / loosen the side cover bolts to freely spin the the assembly and torque to spec when you have selected all of the proper shims for final assembly. If you are using an OEM side cover or Frontline Fabrication transfer case brace, install your O-ring. If you are using a Magnus side cover without modification, use RTV sealant, then install. If you are using a modified Magnus side cover with o-ring groove cut, install your O-ring.
*NOTE: DO NOT FORGET TO STAKE YOUR SHAFT NUT BEFORE INSTALLING THE TAIL HOUSING!!!
*NOTE: Prior to installing the tail housing, do not forget to install your tailshaft oil guide if you are using a stock gearset. If you are using a 300m shaft modified gearset or the Magnus / Brena gearset in a machined tailhousing, REMOVE THE OIL GUIDE!! Also, use some petroleum jelly or assembly gel on the slip yoke bushing before installing the tail housing.
Tail Housing Bolts - 22 ft/lb, star pattern, torqued evenly. Use the equivalent of Permatex Ultra Grey or Ultra Black RTV sealant on the tail housing mounting flange.

Part DescriptionPart #Thickness (SAE)Thickness (mm)
Transfer Case Inner Drive Backlash AdjustmentMD7465100.04211.07
Transfer Case Inner Drive Backlash AdjustmentMD7465110.04331.10
Transfer Case Inner Drive Backlash AdjustmentMD7567550.04451.13
Transfer Case Inner Drive Backlash AdjustmentMD7567560.04571.16
Transfer Case Inner Drive Backlash AdjustmentMD7567570.04691.19
Transfer Case Inner Drive Backlash AdjustmentMD7567580.04801.22
Transfer Case Inner Drive Backlash AdjustmentMD7567590.04921.25
Transfer Case Inner Drive Backlash AdjustmentMD7261670.05041.28
Transfer Case Inner Drive Backlash AdjustmentMD7261680.05161.31
Transfer Case Inner Drive Backlash AdjustmentMD7261690.05281.34
Transfer Case Inner Drive Backlash AdjustmentMD7243260.05391.37
Transfer Case Inner Drive Backlash AdjustmentMD7243270.05511.40
Transfer Case Inner Drive Backlash AdjustmentMD7243280.05631.43
Transfer Case Inner Drive Backlash AdjustmentMD7243290.05751.46
Transfer Case Inner Drive Backlash AdjustmentMD7243300.05871.49
Transfer Case Inner Drive Backlash AdjustmentMD7243310.05981.52
Transfer Case Inner Drive Backlash AdjustmentMD7243320.06101.55
Transfer Case Inner Drive Backlash AdjustmentMD7243330.06221.58
Transfer Case Inner Drive Backlash AdjustmentMD7243340.06341.61
Transfer Case Inner Drive Backlash AdjustmentMD7243350.06461.64
Transfer Case Inner Drive Backlash AdjustmentMD7243360.06571.67
Transfer Case Inner Drive Backlash AdjustmentMD7243370.06691.70
Transfer Case Inner Drive Backlash AdjustmentMD7243380.06811.73
Transfer Case Inner Drive Backlash AdjustmentMD7243390.06931.76
Transfer Case Inner Drive Backlash AdjustmentMD7243400.07051.79
Transfer Case Inner Drive Backlash AdjustmentMD7243410.07171.82
Transfer Case Inner Drive Backlash AdjustmentMD7243420.07281.85
Transfer Case Inner Drive Backlash AdjustmentMD7243430.07401.88
Transfer Case Inner Drive Backlash AdjustmentMD7243440.07521.91
Transfer Case Outer Drive Side Cover PreloadMN1682450.03860.98
Transfer Case Outer Drive Side Cover PreloadMN1682460.04211.07
Transfer Case Outer Drive Side Cover PreloadMN1682470.04571.16
Transfer Case Outer Drive Side Cover PreloadMN1682480.04921.25
Transfer Case Outer Drive Side Cover PreloadMD7236000.05281.34
Transfer Case Outer Drive Side Cover PreloadMD7236010.05391.37
Transfer Case Outer Drive Side Cover PreloadMD7236020.05511.40
Transfer Case Outer Drive Side Cover PreloadMD7236030.05631.43
Transfer Case Outer Drive Side Cover PreloadMD7236040.05751.46
Transfer Case Outer Drive Side Cover PreloadMD7236050.05871.49
Transfer Case Outer Drive Side Cover PreloadMD7236060.05981.52
Transfer Case Outer Drive Side Cover PreloadMD7236070.06101.55
Transfer Case Outer Drive Side Cover PreloadMD7236080.06221.58
Transfer Case Outer Drive Side Cover PreloadMD7236090.06341.61
Transfer Case Outer Drive Side Cover PreloadMD7261700.06461.64
Transfer Case Outer Drive Side Cover PreloadMD7261710.06571.67
Transfer Case Outer Drive Side Cover PreloadMD7567600.06691.70
Transfer Case Outer Drive Side Cover PreloadMD7567610.06811.73
Transfer Case Outer Drive Side Cover PreloadMD7567620.06931.76
Transfer Case Outer Drive Side Cover PreloadMD7567630.07051.79
Transfer Case Outer Drive Side Cover PreloadMD7567640.07171.82
Transfer Case Pinion Shaft Bearing PreloadMD7261720.04691.19
Transfer Case Pinion Shaft Bearing PreloadMD7220810.04801.22
Transfer Case Pinion Shaft Bearing PreloadMD7220820.04921.25
Transfer Case Pinion Shaft Bearing PreloadMD7220830.05041.28
Transfer Case Pinion Shaft Bearing PreloadMD7220840.05161.31
Transfer Case Pinion Shaft Bearing PreloadMD7220850.05281.34
Transfer Case Pinion Shaft Bearing PreloadMD7220860.05391.37
Transfer Case Pinion Shaft Bearing PreloadMD7220870.05511.40
Transfer Case Pinion Shaft Bearing PreloadMD7220880.05631.43
Transfer Case Pinion Shaft Bearing PreloadMD7220890.05751.46
Transfer Case Pinion Shaft Bearing PreloadMD7220900.05871.49
Transfer Case Pinion Shaft Bearing PreloadMD7220910.05981.52
Transfer Case Pinion Shaft Bearing PreloadMD7220920.06101.55
Transfer Case Pinion Shaft Bearing PreloadMD7220930.06221.58
Transfer Case Pinion Shaft Bearing PreloadMD7220940.06341.61
Transfer Case Pinion Shaft Bearing PreloadMD7220950.06461.64
Transfer Case Pinion Shaft Bearing PreloadMD7220960.06571.67
Transfer Case Pinion Shaft Bearing PreloadMD7220970.06691.70
Transfer Case Pinion Shaft Bearing PreloadMD7220980.06811.73
Transfer Case Pinion Shaft Bearing PreloadMD7220990.06931.76
Transfer Case Pinion Shaft Bearing PreloadMD7221000.07051.79
Transfer Case Pinion Shaft Bearing PreloadMD7221010.07171.82
Transfer Case Pinion Shaft Bearing PreloadMD7221020.07281.85
Transfer Case Pinion Shaft Bearing PreloadMD7221030.07401.88
Transfer Case Pinion Shaft Bearing PreloadMD7221040.07521.91
Transfer Case Pinion Shaft Bearing PreloadMD7221050.07641.94
Transfer Case Mid Housing Spacer PlateMD7203530.00510.13
Transfer Case Mid Housing Spacer PlateMD7203540.00630.16
Transfer Case Mid Housing Spacer PlateMD7203550.00750.19
Transfer Case Mid Housing Spacer PlateMD7203560.00870.22
Transfer Case Mid Housing Spacer PlateMD7203570.00980.25
Transfer Case Mid Housing Spacer PlateMD7203580.01100.28
Transfer Case Mid Housing Spacer PlateMD7203590.01220.31
Transfer Case Mid Housing Spacer PlateMD7203600.01340.34
Transfer Case Mid Housing Spacer PlateMD7203610.01460.37
Transfer Case Mid Housing Spacer PlateMD7203620.01570.4
Transfer Case Mid Housing Spacer PlateMD7203630.01690.43
Transfer Case Mid Housing Spacer PlateMD7203640.01810.46
Transfer Case Mid Housing Spacer PlateMD7203650.01930.49
Transfer Case Mid Housing Spacer PlateMD7203660.02050.52

TRANSMISSION SHIMMING VALUES AND SHIMS:

PPG DOGBOX GEARSETS
Input Shaft --> 0.007" PRELOAD
Intermediate Shaft --> 0.007" - 0.008" PRELOAD
Center Differential --> 0.007" - 0.008" PRELOAD
Output Shaft --> 0.007" - 0.008" PRELOAD
Front Differential --> 0.002" - .0067" ENDPLAY

----------------------------------------------------------------------------------------------------------------
HELICAL GEARSETS (OEM, Liberty Face Plated)
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

*For solder crush method testing, use 0.062" solder for the input shaft, intermediate shaft and front diff. Use 3/32" solder for the center differential and output pinion shaft.
SHIMSDSM Input Shaft and Front Differential
Part DescriptionPart NumberID NumberThickness (in)
Shim - Input Shaft / Front DiffMN1681470.440.0173
Shim - Input Shaft / Front DiffMN1681480.480.0189
Shim - Input Shaft / Front DiffMN1681490.520.0205
Shim - Input Shaft / Front DiffMN1681500.560.0220
Shim - Input Shaft / Front DiffMN1681510.600.0236
Shim - Input Shaft / Front DiffMN1681520.640.0252
Shim - Input Shaft / Front DiffMD7276590.650.0256
Shim - Input Shaft / Front DiffMN1681530.680.0268
Shim - Input Shaft / Front DiffMN1681540.720.0283
Shim - Input Shaft / Front DiffMD7276600.740.0291
Shim - Input Shaft / Front DiffMN1681550.760.0299
Shim - Input Shaft / Front DiffMN1681560.800.0315
Shim - Input Shaft / Front DiffMD727661800.0315
Shim - Input Shaft / Front DiffMD720937830.0327
Shim - Input Shaft / Front DiffMN1681570.840.0331
Shim - Input Shaft / Front DiffMD720938860.0338
Shim - Input Shaft / Front DiffMN1681580.880.0346
Shim - Input Shaft / Front DiffMD720939890.0350
Shim - Input Shaft / Front DiffMD720940920.0362
Shim - Input Shaft / Front DiffMN1681590.920.0362
Shim - Input Shaft / Front DiffMD720941950.0374
Shim - Input Shaft / Front DiffMN1681600.960.0378
Shim - Input Shaft / Front DiffMD720942980.0386
Shim - Input Shaft / Front DiffMN1681611.000.0394
Shim - Input Shaft / Front DiffMD72094310.0398
Shim - Input Shaft / Front DiffMD72094440.0409
Shim - Input Shaft / Front DiffMN1681621.040.0409
Shim - Input Shaft / Front DiffMD72094570.0421
Shim - Input Shaft / Front DiffMN1681631.080.0425
Shim - Input Shaft / Front DiffMD710454J0.0433
Shim - Input Shaft / Front DiffMN1681641.120.0441
Shim - Input Shaft / Front DiffMD700270D0.0445
Shim - Input Shaft / Front DiffMN1681651.160.0457
Shim - Input Shaft / Front DiffMD710455K0.0457
Shim - Input Shaft / Front DiffMD710456L0.0468
Shim - Input Shaft / Front DiffMN1681661.200.0472
Shim - Input Shaft / Front DiffMD700271G0.0480
Shim - Input Shaft / Front DiffMN1681671.240.0488
Shim - Input Shaft / Front DiffMD710457M0.0492
Shim - Input Shaft / Front DiffMN1681681.280.0504
Shim - Input Shaft / Front DiffMD710458N0.0504
Shim - Input Shaft / Front DiffMD706574E0.0516
Shim - Input Shaft / Front DiffMN1681691.320.0520
Shim - Input Shaft / Front DiffMD710459O0.0527
Shim - Input Shaft / Front DiffMN1681701.360.0535"
Shim - Input Shaft / Front DiffMD710460P0.0539
Shim - Input Shaft / Front DiffMN1681711.40.0551
Shim - Input Shaft / Front DiffMD7065731.40.0551
Shim - Input Shaft / Front DiffMD710461Q0.0563
Shim - Input Shaft / Front DiffMN1681721.440.0567
Shim - Input Shaft / Front DiffMD710462R0.0575
Shim - Input Shaft / Front DiffMN1681731.480.0583
Shim - Input Shaft / Front DiffMN1681741.520.0598
Part DescriptionPart NumberID NumberThickness (in)
Shim - Intermediate ShaftMD720948800.0315
Shim - Intermediate ShaftMD720949830.0327
Shim - Intermediate ShaftMD720950860.0338
Shim - Intermediate ShaftMD720951890.0350
Shim - Intermediate ShaftMD720952920.0362
Shim - Intermediate ShaftMD720953950.0374
Shim - Intermediate ShaftMD720954980.0386
Shim - Intermediate ShaftMD72095510.0398
Shim - Intermediate ShaftMD72095640.0409
Shim - Intermediate ShaftMD72095770.0421
Shim - Intermediate ShaftMD720958100.0433
Shim - Intermediate ShaftMD720959130.0445
Shim - Intermediate ShaftMD720960160.0457
Shim - Intermediate ShaftMD720961190.0468
Shim - Intermediate ShaftMD720962220.0480
Shim - Intermediate ShaftMD724156220.0480
Shim - Intermediate ShaftMD712346250.0492
Shim - Intermediate ShaftMD724157250.0492
Shim - Intermediate ShaftMD712347280.0504
Shim - Intermediate ShaftMD724158280.0504
Shim - Intermediate ShaftMD712348310.0516
Shim - Intermediate ShaftMD724159310.0516
Shim - Intermediate ShaftMD712349340.0527
Shim - Intermediate ShaftMD712329370.0539
Shim - Intermediate ShaftMD712330400.0551
Shim - Intermediate ShaftMD712331430.0563
Shim - Intermediate ShaftMD712332460.0580
Part DescriptionPart NumberID NumberThickness (in)
Shim - Center DifferentialMD736928130.0445
Shim - Center DifferentialMD736929160.0457
Shim - Center DifferentialMD736751190.0468
Shim - Center DifferentialMD736931220.0480
Shim - Center DifferentialMD726166250.0492
Shim - Center DifferentialMD718517280.0504
Shim - Center DifferentialMD718518310.0516
Shim - Center DifferentialMD718519340.0527
Shim - Center DifferentialMD718520370.0539
Shim - Center DifferentialMD718521400.0551
Shim - Center DifferentialMD718522430.0563
Shim - Center DifferentialMD718523460.0575
Shim - Center DifferentialMD718524490.0587
Shim - Center DifferentialMD718525520.0598
Shim - Center DifferentialMD718526550.0610
Shim - Center DifferentialMD718527580.0622
Shim - Center DifferentialMD718528610.0634
Shim - Center DifferentialMD718529640.0646
Shim - Center DifferentialMD718530670.0657
Shim - Center DifferentialMD718531700.0669
Shim - Center DifferentialMD721959730.0681
Shim - Center DifferentialMD721960760.0692
Shim - Center DifferentialMD721961790.0705
Part DescriptionPart NumberID NumberThickness (in)
Shim - Output ShaftMD7465101.070.0421
Shim - Output ShaftMD7465111.100.0433
Shim - Output ShaftMD7567551.130.0445
Shim - Output ShaftMD7567561.160.0457
Shim - Output ShaftMD7567571.190.0469
Shim - Output ShaftMD7567581.220.0480
Shim - Output ShaftMD7567591.250.0492
Shim - Output ShaftMD726167280.0504
Shim - Output ShaftMD726168310.0516
Shim - Output ShaftMD726169340.0527
Shim - Output ShaftMD724326370.0539
Shim - Output ShaftMD724327400.0551
Shim - Output ShaftMD724328430.0563
Shim - Output ShaftMD724329460.0575
Shim - Output ShaftMD724330490.0587
Shim - Output ShaftMD724331520.0598
Shim - Output ShaftMD724332550.0610
Shim - Output ShaftMD724333580.0622
Shim - Output ShaftMD724334610.0634
Shim - Output ShaftMD724335640.0646
Shim - Output ShaftMD724336670.0657
Shim - Output ShaftMD724337700.0669
Shim - Output ShaftMD724338730.0681
Shim - Output ShaftMD724339760.0692
Shim - Output ShaftMD724340790.0705
Shim - Output ShaftMD724341820.0716
Shim - Output ShaftMD724342850.0728
Shim - Output ShaftMD724343880.0740
Shim - Output ShaftMD724344910.0751
 
Amazing information, thank you! I just got my FF transfer case brace and I had no idea if I was shimming it correctly.
I'm always here to help, simply ask questions and I can answer!
 
Awesome info as always! I’m actually in the midst of doing this with my trans using the boostin bearing plate and I’m having a hell of a time. The outer races don’t just fall out of the housing like they did stock. They have to be pressed in. Making checking the preloads extraordinarily difficult. Kind of at a loss on what to do if you have any tips. Thanks again for everything you do. Hope you’re doing well.
 
Awesome info as always! I’m actually in the midst of doing this with my trans using the boostin bearing plate and I’m having a hell of a time. The outer races don’t just fall out of the housing like they did stock. They have to be pressed in. Making checking the preloads extraordinarily difficult. Kind of at a loss on what to do if you have any tips. Thanks again for everything you do. Hope you’re doing well.
I used a lot of gear oil to get them to slide relatively easy and had to lightly tap them in, but shimmed up good
 
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