Transmission Disassemble. Pontiac Vibe - FWD 2009

GM Service Manual Online

For 1990-2009 cars only

Makes 🢒 Pontiac 🢒 2009 🢒 Vibe - FWD 🢒 Transmission 🢒 Manual Transmission - MVE 5 Speed 🢒 Transmission Disassemble

Object Number: 2010610 Size: SH

Remove the manual transmission filler plug and gasket from the manual transmission case.

Object Number: 2010612 Size: SH

Remove the drain plug sub-assembly and gasket from the manual transmission case.

Object Number: 2010616 Size: SH

Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
Remove the O-ring from the speedometer driven hole cover sub-assembly.
Separate the back-up light switch wire harness from the clamps.
Remove the back-up light switch assembly and gasket from the manual transmission case.

Object Number: 2010623 Size: SH

Remove the bolts (1, 2), nut (3), and selecting bellcrank assembly from the manual transmission case.
Remove the control bellcrank dust cover.

Object Number: 2010626 Size: SH

Remove the nut (1) and washer.

Object Number: 2010628 Size: SH

Using a brass bar and a hammer, remove the lock pin.
Remove the floor shift control shift lever and dust boot.

Object Number: 2010629 Size: SH

Remove the nut (1) and washer.

Object Number: 2010630 Size: SH

Using a brass bar and a hammer, remove the lock pin.
Remove the shift lever damper and dust boot.

Object Number: 2010632 Size: SH

Place the manual transaxle assembly on wooden blocks (1, 2).

Object Number: 2010633 Size: SH

Remove the No. 1 lock ball assembly (1) from the manual transmission case.

Object Number: 2010634 Size: SH

Remove the shift guide pin (1) and washer from the manual transmission case.

Object Number: 2010635 Size: SH

Remove the bolts (1-4), control shaft cover and gasket from the manual transmission case.

Object Number: 2010637 Size: SH

Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.

Object Number: 2010639 Size: SH

Remove the shift and select lever shaft assembly from the manual transmission case.

Object Number: 2010643 Size: SH

Remove the bolts.

Object Number: 2010644 Size: SH

Note: Do not damage the manual transmission case.

Using a plastic hammer, carefully tap the projections (1, 2, 3, 4) of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.

Object Number: 2010646 Size: SH

Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.

Object Number: 2010648 Size: SH

Engage the gears simultaneously to lock the transmission.
Remove the manual transmission output shaft rear set nut.
Disengage the gears.

Object Number: 2010655 Size: SH

Remove the gear shift fork lock bolt (1) from the No. 3 gear shift fork.

Object Number: 2010658 Size: SH

Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.

Object Number: 2010659 Size: SH

Using a dial indicator, measure the 5th gear thrust clearance.

Specifications

•	Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)

•	Maximum clearance - 0.55 mm (0.0217 in)

If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

Object Number: 2010661 Size: SH

Using a dial indicator, measure the 5th gear radial clearance.

Specifications

•	Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)

•	Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)

•	Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

Object Number: 2010665 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, tap out the snap ring.

Object Number: 2010666 Size: SH

Using a screwdriver, remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.
Using a suitable puller, remove the No. 3 transmission clutch hub, 5th gear, and No. 3 synchronizer ring from the input shaft.

Object Number: 2010670 Size: SH

Remove the synchromesh shifting keys and synchromesh shifting key spring from the No. 3 transmission clutch hub.

Object Number: 2010672 Size: SH

Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
Using a suitable puller, remove the 5th driven gear from the output shaft.

Object Number: 2010680 Size: SH

Remove the bolts (1-5) and rear bearing retainer from the manual transmission case.

Object Number: 2010682 Size: SH

Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.

Object Number: 2010685 Size: SH

Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.

Object Number: 2010686 Size: SH

Remove the reverse idler gear shaft bolt (1) and gasket from the manual transmission case.

Object Number: 2010691 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.

Object Number: 2010692 Size: SH

Using a hexagon wrench, remove the shift detent ball plugs from the manual transmission case.

Object Number: 2010694 Size: SH

Using a magnetic pick-up tool, remove the shift spring seats, shift detent ball springs, and shift detent balls from the manual transmission case.

Object Number: 2010695 Size: SH

Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.

Object Number: 2010697 Size: SH

Using a magnetic pick-up tool, remove the seat, spring, and ball from the transaxle case.

Object Number: 2010701 Size: SH

Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.

Object Number: 2010707 Size: SH

Remove the bolts (1-3) from the transaxle case.

Object Number: 2010709 Size: SH

Remove the bolts (1-13) from the manual transmission case.

Object Number: 2010711 Size: SH

Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.

Object Number: 2010713 Size: SH

Remove the reverse idler gear sub-assembly, thrust washer, and reverse idler gear shaft from the transaxle case.

Object Number: 2010717 Size: SH

Remove the bolts (1, 2) and reverse shift arm bracket assembly from the transaxle case.

Object Number: 2010720 Size: SH

Remove the bolts (1, 2) from the No. 2 gear shift fork and No. 1 gear shift head.

Object Number: 2010722 Size: SH

Remove the No. 2 gear shift fork shaft (1) and No. 1 gear shift head from the transaxle case.

Object Number: 2010724 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, tap out the snap ring.

Object Number: 2010726 Size: SH

Remove the shift fork set bolt (2) and No. 1 gear shift fork shaft (1) from the No. 1 gear shift fork.

Object Number: 2010728 Size: SH

Remove the No. 1 gear shift fork (1).

Object Number: 2010731 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.

Object Number: 2010733 Size: SH

Remove the No. 3 gear shift fork shaft (1) together with the reverse shift fork and No. 2 gear shift fork from the manual transaxle case.

Object Number: 2010735 Size: SH

Using a magnetic pick-up tool, remove the reverse shift fork balls from the reverse shift fork.

Object Number: 2010736 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, tap the snap ring out of the No. 3 shift fork shaft.
Remove the reverse shift fork from the No. 3 gear shift fork shaft.

Object Number: 2010740 Size: SH

Remove the input shaft assembly and output shaft assembly from the transaxle case.

Object Number: 2010742 Size: SH

Remove the differential case assembly from the transaxle case.

Object Number: 2010747 Size: SH

Remove the bolt (1) and manual transaxle case receiver from the transaxle case.

Object Number: 2010748 Size: SH

Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.

Object Number: 2010750 Size: SH

Using a pin punch (5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.

Object Number: 2010752 Size: SH

Note: Do not damage the No. 1 oil receiver pipe.

Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.

Object Number: 2010753 Size: SH

Note: Do not damage the No. 2 oil receiver pipe.

Remove the bolt (1) and No. 2 oil receiver pipe from the manual transmission case.

Object Number: 2010755 Size: SH

Remove the bolt (1) and bearing lock plate from the transaxle case.

Object Number: 2010758 Size: SH

Remove the transmission magnet from the transaxle case.
Remove the input shaft front bearing from the transaxle case.

Object Number: 2010768 Size: SH

Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
Remove the output shaft front bearing from the transaxle case.

Object Number: 2010774 Size: SH

Remove the output shaft cover from the transaxle case.

Object Number: 2010778 Size: SH

Using a suitable puller (1), remove the front differential case front tapered roller bearing (outer race) and plate washer from the transaxle case.

Object Number: 2010780 Size: SH

Using a suitable puller (4), remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.

Object Number: 2010781 Size: SH

Using a suitable driver (1) and a hammer, remove the transaxle case oil seal from the transaxle case.
Remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
Remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

Object Number: 2010787 Size: SH

Using a suitable driver (2) and a hammer, drive out the transmission case oil seal from the manual transmission case.

Object Number: 2010788 Size: SH

Using a screwdriver and a hammer, remove the shift and select lever shaft oil seal.

Object Number: 2010791 Size: SH

Using a suitable driver (1) and a plastic hammer, remove the shift and select lever shaft slide ball bearing.

Object Number: 2010793 Size: SH

Inspect the No. 3 synchronizer ring. Check for wear and damage.
Coat the 5th gear cone with gear oil.
Turn the synchronizer ring in one direction while pushing it against the 5th gear cone.
Check that the ring locks.

If the synchronizer ring does not lock, replace the synchronizer ring.

Object Number: 2010794 Size: SH

Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Specifications

•	Standard clearance - 0.75-1.65 mm (0.0295-0.0249 in)

•	Maximum clearance - 0.75 mm (0.0295 in)

If the clearance is less than the minimum, replace the synchronizer ring.

Object Number: 2010798 Size: SH

Check the sliding condition between the No. 3 transmission hub sleeve and the No. 3 transmission clutch hub.
Check that the edges of the No. 3 transmission hub sleeve spline gear are not worn down.

Object Number: 2010801 Size: SH

Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 gear shift fork (B), and calculate the clearance.

Specification
Standard Clearance (A-B) 0.3-0.5 mm (0.0118-0.0197 in)

If the clearance exceeds the standard, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.

Object Number: 2010803 Size: SH

Inspect the 5th gear. Using a caliper gage, measure the inside diameter.

Specifications

•	Standard inside diameter - 29.915-29.931 mm (1.1778-1.1783 in)

•	Maximum inside diameter - 29.931 mm (1.1783 in)

If the inside diameter exceeds the maximum, replace the 5th gear.

Object Number: 2011037 Size: SH

Using a feeler gage, measure the 4th gear thrust clearance.

Specifications

•	Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)

•	Maximum clearance - 0.55 mm (0.0217 in)

If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.

Object Number: 2011043 Size: SH

Using a dial indicator, measure the 3rd gear thrust clearance.

Specifications

•	Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)

•	Maximum clearance - 0.35 mm (0.0138 in)

If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

Object Number: 2011045 Size: SH

Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

Specifications

•	Standard clearance, NSK made bearing - 0.009-0.050 mm (0.0003-0.0019 in)

•	Standard clearance, KOYO made bearing - 0.009-0.050 mm (0.0003-0.0019 in)

•	Maximum clearance, NSK made bearing - 0.050 mm (0.0019 in)

•	Maximum clearance, KOYO made bearing - 0.050 mm (0.0019 in)

If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

Object Number: 2011046 Size: SH

Using a dial indicator, measure the 3rd gear radial clearance.

Specifications

•	Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)

•	Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)

•	Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

Object Number: 2011063 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.

Object Number: 2011065 Size: SH

Note: Support the input shaft assembly by hand to prevent it from dropping off.

Using a press (1), remove the input shaft rear radial ball bearing and 4th gear from the input shaft.

Object Number: 2011067 Size: SH

Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.

Object Number: 2011072 Size: SH

Remove the 4th gear synchronizer ring from the No. 2 transmission clutch hub.

Object Number: 2011079 Size: SH

Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.

Object Number: 2011082 Size: SH

Note: Support the input shaft assembly by hand to prevent it from dropping off.

Using a press (1), remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.

Object Number: 2011084 Size: SH

Remove the 3rd gear synchronizer ring from the 3rd gear.

Object Number: 2011087 Size: SH

Remove the 3rd gear needle roller bearing from the input shaft.

Object Number: 2011088 Size: SH

Note: Use a shop rag or piece of cloth to keep the shifting keys and shifting key springs from flying off.

Remove the No. 2 transmission hub sleeve, shifting keys, and shifting key springs from the No. 2 transmission clutch hub.

Object Number: 2011096 Size: SH

Using a dial indicator, check the input shaft runout.

Specification
Maximum runout - 0.015 mm (0.0005 in)

If the runout exceeds the maximum, replace the input shaft.

Object Number: 2011098 Size: SH

Using a micrometer, measure the outer diameter of the input shaft journal surface at the locations indicated.

Standard Outer Diameter

•	Part 1 - 24.885-24.900 mm (0.9797-0.9803 in)

•	Part 2 - 28.991-29.006 mm (1.1414-1.1420 in)

•	Part 3 - 30.985-31.000 mm (1.2198-1.2204 in)

•	Part 4 - 24.985-25.000 mm (0.9836-0.9842 in)

Minimum Outer Diameter

•	Part 1 - 24.885 mm (0.9797 in)

•	Part 2 - 28.991 mm (1.1414 in)

•	Part 3 - 30.985 mm (1.2198 in)

•	Part 4 - 24.985 mm (0.9836 in)

If any of the outer diameters are less than the minimum, replace the input shaft.

Object Number: 2011100 Size: SH

Using a cylinder gage, measure the inside diameter of the 4th gear.

Specifications

•	Standard Inside Diameter - 34.015-34.031 mm (1.3391-1.3398 in)

•	Maximum Inside Diameter - 34.031 mm (1.3398 in)

If the inside diameter exceeds the maximum, replace the 4th gear.

Object Number: 2011103 Size: SH

Using a cylinder gage, measure the inside diameter of the 3rd gear.

Specifications

•	Standard Inside Diameter - 36.015-36.031 mm (1.4179-1.4185 in)

•	Maximum Inside Diameter - 36.031 mm (1.4185 in)

If the inside diameter exceeds the maximum, replace the 3rd gear.

Object Number: 2011104 Size: SH

Inspect the 4th gear synchronizer ring, check for wear and damage.
Coat the 4th gear cone with gear oil.
Turn the synchronizer ring in one direction while pushing it against the 4th gear cone.
Check that the ring locks.

If the synchronizer ring does not lock, replace the synchronizer ring.

Object Number: 2011106 Size: SH

Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Specifications

•	Standard Clearance - 0.65-1.75 mm (0.0256-0.0689 in)

•	Minimum Clearance - 0.65 mm (0.0256 in)

If the clearance is less than the minimum, replace the synchronizer ring.

Object Number: 2011107 Size: SH

Inspect the 3rd gear synchronizer ring. Check for wear and damage.
Coat the 3rd gear cone with gear oil.
Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone.
Check that the ring locks.

If the synchronizer ring does not lock, replace the synchronizer ring.

Object Number: 2011108 Size: SH

Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Specifications

•	Standard Clearance - 0.75-1.65 mm (0.0295-0.0649 in)

•	Minimum Clearance - 0.75 mm (0.0295 in)

If the clearance is less than the minimum, replace the synchronizer ring.

Object Number: 2011151 Size: SH

Using a feeler gage, measure the 1st gear thrust clearance.

Specifications

•	Standard Clearance - 0.10-0.40 mm (0.0039-0.0157 in)

•	Minimum Clearance - 0.40 mm (0.0157 in)

If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.

Object Number: 2011152 Size: SH

Using a dial indicator, measure the 2nd gear thrust clearance.

Specifications

•	Standard Clearance - 0.10-0.55 mm (0.0039-0.0217 in)

•	Minimum Clearance - 0.55 mm (0.0217 in)

If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

Object Number: 2011154 Size: SH

Using a dial indicator, measure the 1st gear radial clearance.

Specifications

•	Standard Clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)

•	Standard Clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)

•	Maximum Clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum Clearance, KOYO made bearing - 0.058 mm (0.0022 in)

If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or input shaft.

Object Number: 2011156 Size: SH

Using a dial indicator, measure the 2nd gear radial clearance.

Specifications

•	Standard Clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)

•	Standard Clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)

•	Maximum Clearance, NSK made bearing - 0.056 mm (0.0022 in)

•	Maximum Clearance, KOYO made bearing - 0.058 mm (0.0022 in)

If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or input shaft.

Object Number: 2011158 Size: SH

Using a press (1), remove the output shaft rear bearing and 4th driven gear from the output shaft.

Object Number: 2011159 Size: SH

Remove the output gear spacer (1) from the output shaft.

Object Number: 2011160 Size: SH

Using a press (1), remove the 3rd driven gear with the 2nd gear from the output shaft.

Object Number: 2011161 Size: SH

Remove the 2nd gear needle roller bearing (1) and 2nd gear bearing spacer from the output shaft.

Object Number: 2011163 Size: SH

Remove the No. 2 synchronizer ring set from the output shaft.

Object Number: 2011164 Size: SH

Note: Use a shop rag or piece of cloth to keep the shaft snap ring from flying off.

Using 2 screwdrivers and a hammer, remove the No. 1 clutch hub shaft snap ring from the output shaft.

Object Number: 2011165 Size: SH

Note: Support the input shaft by hand to prevent it from dropping off.

Using a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.

Object Number: 2011167 Size: SH

Remove the No. 1 synchronizer ring set from the 1st gear.

Object Number: 2011168 Size: SH

Remove the 1st gear needle roller bearing (1) from the output shaft.

Object Number: 2011170 Size: SH

Remove the 1st gear thrust washer (1) from the output shaft.

Object Number: 2011171 Size: SH

Remove the 1st gear thrust washer pin or ball (1) from the output shaft.

Object Number: 2011173 Size: SH

Note: Use a shop rag or piece of cloth to keep the shifting keys and shifting key springs from flying off.

Remove the reverse gear, synchromesh shifting keys, and synchromesh shifting key springs from the No. 1 transmission clutch hub.

Object Number: 2011174 Size: SH

Using a dial indicator and V-blocks, check the output shaft runout.

Specification
Maximum Runout - 0.015 mm (0.0005 in)

If the runout exceeds the maximum, replace the output shaft.

Object Number: 2011176 Size: SH

Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.

Specifications

•	Standard Outer Diameter, Part 1 - 31.985-32.000 mm (1.2592-1.2598 in)

•	Standard Outer Diameter, Part 2 - 37.985-38.000 mm (1.4955-1.4961 in)

•	Standard Outer Diameter, Part 3 - 32.985-33.000 mm (1.2986-1.2992 in)

If any of the outer diameters are less than the minimum, replace the output shaft.

Object Number: 2011177 Size: SH

Using a cylinder gage, measure the inside diameter of the 2nd gear.

Specifications

•	Standard Inside Diameter - 38.015-38.031 mm (1.4967-1.4972 in)

•	Maximum Inside Diameter - 38.031 mm (1.4972 in)

If the inside diameter exceeds the maximum, replace the 1st gear.
Using a cylinder gage, measure the inside diameter of the 1st gear.

Specifications

•	Standard Inside Diameter - 44.015-44.031 mm (1.7328-1.7335 in)

•	Maximum Inside Diameter - 44.031 mm (1.7335 in)

If the inside diameter exceeds the maximum, replace the 1st gear.

Object Number: 2011178 Size: SH

Using a micrometer, measure the 1st gear thrust washer.

Specifications

•	Standard Thickness - 5.975-6.025 mm (0.2352-0.2372 in)

•	Minimum Thickness - 5.975 mm (0.2352 in)

If the thickness is less than the minimum, replace the 1st gear thrust washer.

Object Number: 2011181 Size: SH

Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
Install the inner ring onto the 2nd gear.

Object Number: 2011182 Size: SH

Install the middle ring onto the 2nd gear.

Object Number: 2011187 Size: SH

Install the outer ring onto the 2nd gear.

Object Number: 2011185 Size: SH

Check for wear and damage.
Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
Check that the ring set locks.

If the synchronizer ring set does not lock, replace the synchronizer ring set.

Object Number: 2011186 Size: SH

Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Specifications

•	Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)

•	Minimum Clearance - 0.60 mm (0.0236 in)

If the clearance is less than the minimum, replace the synchronizer ring set.

Object Number: 2011191 Size: SH

Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
Install the inner ring onto the 1st gear.

Object Number: 2011192 Size: SH

Install the middle ring onto the 1st gear.

Object Number: 2011193 Size: SH

Install the outer ring onto the 1st gear.

Object Number: 2011194 Size: SH

Check for wear and damage.
Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
Check that the ring set locks.

If the synchronizer ring set does not lock, replace the synchronizer ring set.

Object Number: 2011195 Size: SH

Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Specifications

•	Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)

•	Minimum Clearance - 0.60 mm (0.0236 in)

If the clearance is less than the minimum, replace the synchronizer ring set.

Object Number: 2011239 Size: SH

Remove the speedometer drive gear from the front differential case.

Object Number: 2011241 Size: SH

Place matchmarks (1) on the front differential ring gear and the front differential case.
Remove the bolts.

Object Number: 2011243 Size: SH

Using a plastic hammer, remove the front differential ring gear from the front differential case.

Object Number: 2011244 Size: SH

Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Specification
Standard Backlash - 0.05 to 0.20 mm (0.0020 to 0.0079 in)

If the backlash is out of the specification, replace the side gear thrust washers.

Object Number: 2011248 Size: SH

Using a chisel and a hammer, loosen the staked part of the front differential case.

Object Number: 2011250 Size: SH

Using a pin punch (3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.

Object Number: 2011251 Size: SH

Remove the front No. 1 differential pinion shaft from the front differential case.

Object Number: 2011253 Size: SH

Note: While rotating the front differential pinion, remove the pinions and side gears.

Remove the front differential pinions, front differential pinion thrust washers, No. 1 front differential side gear thrust washers, and front differential side gears from the front differential case.

Object Number: 2011254 Size: SH

Using a micrometer, measure the thickness of the front differential pinion thrust washer.

Specification
Minimum Thickness - 0.94 mm (0.0370 in)

If the thickness is less than the minimum, replace the front differential pinion thrust washer.

Object Number: 2011256 Size: SH

Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

Specification
Minimum Outer Diameter - 16.982 mm (0.6685 in)

If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.