## 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 distance collar | I.D. |  | 32.00-32.01 mm (1.2598-1.2602 in.) | 32.02 mm (1.261 in.)
O.D. |  | 38.989-39.000 mm (1.5350-1.5354 in.) | 38.94 mm (1.533 in.)
Length | A | 51.95-52.05 mm (2.045-2.049 in.) | -
B | 24.03-24.08 mm (0.946-0.947 in.) | -
Mainshaft 6th gear distance collar | I.D. |  | 28.00-28.01 mm (1.102-1.103 in.) | 28.02 mm (1.103 in.)
O.D. |  | 34.989-35.000 mm (1.3775-1.3779 in.) | 34.940 mm (1.3756 in.)
Length |  | 24.03-24.08 mm (0.946-0.947 in.) | -
Reverse idler gear | I.D. |  | 20.016-20.043 mm (0.7880-0.7891 in.) | 20.90 mm (0.832 in.)
Gear-to-reverse gear shaft clearance |  | 0.036-0.084 mm (0.0014-0.0033 in.) | 0.16 mm (0.006 in.)
Double cone synchro | Outer synchro ring-to-synchro cone clearance | Ring pushed against gear | 0.70-1.19 mm (0.028-0.047 in.) | 0.3 mm (0.012 in.)
Synchro cone-to-gear clearance | Ring pushed against gear | 0.50-1.04 mm (0.020-0.041 in.) | 0.3 mm (0.012 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 (0.024 in.)
Triple cone synchro | Outer synchro ring-to-synchro cone clearance | Ring pushed against gear | 0.70-1.19 mm (0.028-0.047 in.) | 0.3 mm (0.012 in.)
Synchro cone-to-gear clearance | Ring pushed against gear | 0.50-1.04 mm (0.020-0.041 in.) | 0.3 mm (0.012 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 (0.024 in.)
Shift fork | Finger thickness |  | 7.4-7.6 mm (0.29-0.30 in.) | -
Fork-to-synchro sleeve clearance |  | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.039 in.)
Reverse shift fork | Finger thickness |  | 13.4-13.7 mm (0.527-0.539 in.) | -
Fork-to-reverse idler gear clearance |  | 0.20-0.59 mm (0.007-0.024 in.) | 1.3 mm (0.051 in.)
Shift arm | I.D. |  | 13.973-14.000 mm (0.5501-0.5512 in.) | -
Shift fork diameter at contact area |  | 16.9-17.0 mm (0.665-0.669 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 |  | 14.85-14.95 mm (0.585-0.589 in.) | -
Shift lever | Shaft-to-select lever clearance |  | 0.05-0.25 mm (0.002-0.010 in.) | 0.50 mm (0.020 in.)
Groove (to select lever) |  | 15.00-15.10 mm (0.591-0.594 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.) | 0.1 mm (0.004 in.)
Driveshaft contact area I.D. |  | 28.025-28.045 mm (1.1033-1.1041 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.) | 0.15 mm (0.006 in.)
80 mm shim | 80 mm shim-to-bearing outer race clearance in transmission housing |  | 0-0.10 mm (0-0.0039 in.) | Adjust

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