Operation CHARM: Car repair manuals for everyone.

Part 2 of 2

Reverse idler gear I.D. Standard or new 20.016 - 20.043 mm
Service limit 20.90 mm
Gear-to-reverse gear shaft clearance Standard or new 0.036 - 0.084 mm
Service limit 0.16 mm
Synchro ring Ring-to-gear clearance Ring pushed against gear Standard or new 0.70 - 1.49 mm
Service limit 0.4 mm
Double cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear Standard or new 0.70 - 1.19 mm
Service limit 0.3 mm
Synchro cone-to-gear clearance Ring pushed against gear Standard or new 0.50 - 1.04 mm
Service limit 0.3 mm
Outer synchro ring-to-gear cone clearance Ring pushed against gear Standard or new 0.95 - 1.68 mm
Service limit 0.6 mm
Triple cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear Standard or new 0.70 - 1.19 mm
Service limit 0.3 mm
Synchro cone-to-gear clearance Ring pushed against gear Standard or new 0.50 - 1.04 mm
Service limit 0.3 mm
Outer synchro ring-to-gear cone clearance Ring pushed against gear Standard or new 0.95 - 1.68 mm
Service limit 0.6 mm
Shift fork Finger thickness Standard or new 7.4 - 7.6 mm
Fork-to-synchro sleeve clearance Standard or new 0.35 - 0.65 mm
Service limit 1.0 mm
Reverse shift fork Finger thickness Standard or new 13.4 - 13.7 mm
Fork-to-synchro sleeve clearance Standard or new 0.20 - 0.59 mm
Service limit 1.2 mm
Shift arm I.D Standard or new 13.973 - 14.000 mm
Shift fork diameter at contact area Standard or new 16.9 - 17.0 mm
Shift arm-to-shift lever clearance Standard or new 0.2 - 0.5 mm
Service limit 0.6 mm
Select lever Finger width Standard or new 14.85 - 14.95 mm
Shift lever Shaft-to-select lever clearance Standard or new 0.05 - 0.25 mm
Service limit 0.5 mm
Groove (to select lever) Standard or new 15.00 - 15.10 mm
Shift-to-shift arm clearance Standard or new 0.013 - 0.07 mm
Service limit 0.1 mm
M/T differential carrier Pinion shaft contact area I.D. Standard or new 18.010 - 18.028 mm
Carrier-to-pinion shaft clearance Standard or new 0.027 - 0.057 mm
Service limit 0.1 mm
Driveshaft contact area I.D. Standard or new 28.025 - 28.045 mm
M/T differential pinion gear Backlash Standard or new 0.05 - 0.15 mm
I.D. Standard or new 18.042 - 18.066 mm
Pinion gear-to-pinion shaft clearance Standard or new 0.059 - 0.095 mm
Service limit 0.15 mm
80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing Standard or new 0 - 0.1 mm
Service limit Adjust
Transfer Diameter of tapered roller bearing contact area (transfer shaft) Standard or new 24.975 - 24.990 mm
Service limit 24.92 mm
Diameter of tapered roller bearing contact area (transfer drive gear) Standard or new 40.002 - 40.018 mm
Service limit 38.95 mm
Diameter of tapered roller bearing contact area (driven gear side) Standard or new 35.002 - 35.018 mm
Service limit 34.95 mm
Diameter of tapered roller bearing contact (splined side) Standard or new 26.975 - 26.988 mm
Service limit 26.92 mm
Transfer gear backlash Standard or new 0.06 - 0.16 mm
Service limit Adjust
Total starting torque Standard or new 2.24 - 3.71 Nm
Service limit Adjust