Standards and Service Limits

Manual Transmission and Differential (cont'd)

2-8  
Item Measurement Qualification Standard or New Service Limit
Mainshaft 4th and 5th gears spacer collar I.D.   29.002-29.012 mm

(1.1418-1.1422 in.)

29.060 mm

(1.1441 in.)

O.D.   34.989-35.000 mm

(1.3775-1.3780 in.)

34.930 mm

(1.3752 in.)

Length
A 51.97-52.03 mm

(2.046-2.048 in.)

-
B 24.03-24.06 mm

(0.946-0.947 in.)

-
Reverse idler gear I.D.   15.016-15.043 mm

(0.5912-0.5922 in.)

15.080 mm

(0.5937 in.)

Gear-to-reverse gear shaft clearance   0.032-0.077 mm

(0.0012-0.0030 in.)

0.140 mm

(0.0055 in.)

Synchro ring Ring-to-gear clearance Ring pushed against gear 0.85-1.10 mm

(0.033-0.043 in.)

0.4 mm

(0.016 in.)

Dual cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.5-1.0 mm

(0.02-0.04 in.)

0.3 mm

(0.01 in.)

Synchro cone-to-gear clearance Ring pushed against gear 0.5-1.0 mm

(0.02-0.04 in.)

0.3 mm

(0.01 in.)

Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm

(0.037-0.066 in.)

0.6 mm

(0.02 in.)

Shift fork Finger thickness 1st-2nd and 3rd-4th forks 7.4-7.6 mm

(0.29-0.30 in.)

-
5th fork 6.7-6.9 mm

(0.26-0.27 in.)

-
Fork-to-synchro sleeve clearance   0.35-0.65 mm

(0.014-0.026 in.)

1.00 mm

(0.039 in.)

Reverse shift fork Pawl groove width   13.8-14.1 mm

(0.543-0.555 in.)

15.5 mm (0.610 in.)
Fork-to-reverse idler gear clearance   1.6-2.2 mm

(0.06-0.09 in.)

2.8 mm

(0.11 in.)

Shift arm I.D.   13.973-14.000 mm (0.5501-0.5512 in.) -
Shift fork diameter at contact area   12.9-13.0 mm (0.508-0.512 in.) -
Shift arm-to-shift lever clearance   0.2-0.5 mm

(0.008-0.020 in.)

0.62 mm

(0.024 in.)

Select lever Finger width   14.75-14.95 mm (0.581-0.589 in.) -
Shift lever Shaft-to-select lever clearance   0.05-0.40 mm

(0.002-0.016 in.)

0.6 mm

(0.024 in.)

Groove (to select lever)   15.00-15.15 mm

(0.591-0.596 in.)

-
Shaft-to-shift arm clearance   0.013-0.07 mm

(0.0005-0.003 in.)

0.1 mm

(0.004 in.)

M/T differential carrier Pinion shaft contact area I.D.   18.010-18.028 mm

(0.7091-0.7098 in.)

-
Carrier-to-pinion shaft clearance   0.027-0.057 mm

(0.0011-0.0022 in.)

0.100 mm

(0.0039 in.)

Driveshaft contact area I.D.   26.025-26.045 mm

(1.0246-1.0254 in.)

-
M/T differential pinion gear Backlash   0.05-0.15 mm

(0.002-0.006 in.)

-
I.D.   18.042-18.066 mm

(0.7103-0.7113 in.)

-
Pinion gear-to-pinion shaft clearance   0.059-0.095 mm

(0.0023-0.0037 in.)

0.150 mm

(0.0059 in.)