Operation CHARM: Car repair manuals for everyone.

Part 2 of 2

Countershaft reverse gear I.D. Standard or new 50.009 - 50.025 mm
Thickness Standard or new 26.38 - 26.46 mm
Service limit 26.26 mm
End play Standard or new 0.4 - 0.22 mm
Service limit 0.3 mm
Countershaft reverse gear distance collar O.D. Standard or new 37.989 - 38.000 mm
Length Standard or new 25.53 - 25.58 mm
Secondary shaft Diameter of ball bearing contact area Standard or new 31.002 - 31.013 mm
Service limit 30.95 mm
Diameter of propeller shaft sie tapered roller bearing contact area Standard or new 41.002 - 41.018 mm
Service limit 40.95 mm
Diameter of transmission housing side tapered roller bearing contact area Standard or new 35.009 - 35.025 mm
Service limit 34.96 mm
Runout Standard or new 0.02 mm Maximum
Service limit 0.05 mm
Starting torque (preload) Standard or new 1.86 - 2.84 Nm
Service limit Adjust
Shift fork Finger thickness 1-2 shift fork Standard or new 7.4 - 7.6 mm
3-4 shift fork Standard or new 6.2 - 6.4 mm
5-6 shift fork Standard or new 6.2 - 6.4 mm
Reverse shift fork Standard or new 6.2 - 6.4 mm
Fork-to-synchro sleeve clearance Standard or new 0.35 - 0.65 mm
Service limit 1.00 mm
Groove to 1-2 shift lever Standard or new 7.2 - 17.4 mm
Service limit 17.1 mm
to shift arm A Standard or new 17.2 - 17.4 mm
Service limit 17.1 mm
Shift arm A I.D. Standard or new 16.000 - 16.027 mm
Finger width Standard or new 16.8 - 17.0 mm
Service limit 16.7 mm
Shift arm A-to-shift forks Standard or new 0.2 - 0.6 mm
Service limit 0.7 mm
1-2 shift lever Finger width Standard or new 17.0 - 17.2 mm
Service limit 16.9 mm
Lever-to-shift forks and pieces clearance Standard or new 0 - 0.4 mm
Service limit 0.5 mm
1-2 shift piece Groove to shift arm A Standard or new 17.2 - 17.4 mm
Service limit 17.1 mm
3-4 shift piece Groove to shift arm A Standard or new 17.2 - 17.4 mm
Service limit 17.1 mm
Reverse shift piece Groove to 1-2 shift arm A Standard or new 17.2 - 17.4 mm
Service limit 17.1 mm
to shift arm A Standard or new 17.2 - 17.4 mm
Service limit 17.1 mm
Synchro ring Ring-to-gear clearance (ring pushed against gear) 5th and 6th gears Standard or new 0.75 - 1.00 mm
Service limit 0.4 mm
Reverse gear Standard or new 0.85 - 1.10 mm
Service limit 0.4 mm
Double cone Outer syncro ring-to-synchro cone clearance 1st and 2nd gears Standard or new 0.70 - 1.09 mm
Service limit 0.3 mm
3rd and 4th gears Standard or new 0.90 - 1.39 mm
Service limit 0.3 mm
Synchro cone-to-gear clearance
(ring pushed against gear)
1st, 3rd and 4th gears Standard or new 0.50 - 1.04 mm
Service limit 0.3 mm
2nd gear Standard or new 0.65 - 1.78 mm
Service limit 0.3 mm
Outer synchro ring-to-gear clearance
(ring pushed against gear)
1st, 3rd and 4th gears Standard or new 0.95 - 1.68 mm
Service limit 0.6 mm
2nd gears Standard or new 0.70 - 1.82 mm
Service limit 0.6 mm
Oil pump Inner rotor-to-outer rotor radial clearance Standard or new 1.14 mm Maximum
Service limit 0.20 mm
Rotor-to-transmission housing clearance Radial clearance Standard or new 0.1 - 0.2 mm
Service limit 0.22 mm
Axial clearance Standard or new 0.03 - 0.07 mm
Service limit Adjust