## Standards and Service Limits

#### Manual Transmission and Differential (cont'd)

2-16

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.)

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