GM Service Manual Online
For 1990-2009 cars only
Table 1: Gear Axial Clearance
Table 2: Gear Radial Clearance
Table 3: Output Shaft
Table 4: Input Shaft Bearing Journals - Minimum Diameter
Table 5: Countershaft Bearing Journals - Minimum Diameter
Table 6: Synchronizer Blocker Ring to Gear - Minimum Clearance
Table 7: Synchronizer Sleeve to Shift Fork - Maximum Clearance

Gear Axial Clearance

Application

Standard Clearance Metric

Standard Clearance English

1st Countershaft Gear

0.10-0.43 mm

0.0039-0.0169 in

2nd Countershaft Gear

0.10-0.43 mm

0.0039-0.0169 in

3rd Gear

0.09-0.52 mm

0.0035-0.0204 in

4th Gear

0.12-0.38 mm

0.0047-0.0150 in

6th Gear

0.20-0.49 mm

0.0079-0.0193 in

Reverse Countershaft Gear

0.125-0.375 mm

0.0049-0.0148 in

Reverse Idler Gear

0.10-0.55 mm

0.0039-0.0216 in


Gear Radial Clearance

Application

Standard Clearance Metric

Standard Clearance English

1st Countershaft Gear

0.015-0.067 mm

0.0006-0.0026 in

2nd Countershaft Gear

0.015-0.067 mm

0.0006-0.0026 in

3rd Gear

0.015-0.067 mm

0.0006-0.0026 in

4th Gear

0.015-0.067 mm

0.0006-0.0026 in

6th Gear

0.015-0.065 mm

0.0006-0.0025 in

Reverse Countershaft Gear

0.015-0.065 mm

0.0006-0.0025 in

Reverse Idler Gear

0.015-0.050 mm

0.0006-0.0020 in


Output Shaft

Application

Specification

Metric

English

Runout - Maximum

0.136 mm

0.0053 in

Flange Thickness - Maximum

11.3 mm

0.4449 in


Input Shaft Bearing Journals - Minimum Diameter

Application

Specification

Metric

English

3rd Gear

44.985 mm

1.7710 in

4th Gear

44.985 mm

1.7710 in

6th Gear

41.985 mm

1.6529 in


Countershaft Bearing Journals - Minimum Diameter

Application

Specification

Metric

English

1st Countershaft Gear Bearing

47.985 mm

1.8891 in

2nd Countershaft Gear Bearing

53.985 mm

2.1254 in

Reverse

44.985 mm

1.7710 in

Reverse Idler Gear

27.937 mm

1.0999 in


Synchronizer Blocker Ring to Gear - Minimum Clearance

Application

Specification

Metric

English

1st, 2nd

0.88 mm

0.035 in

3rd

0.8 mm

0.031 in

4th, 5th, 6th

0.7 mm

0.027 in

Reverse

0.9 mm

0.035 in


Synchronizer Sleeve to Shift Fork - Maximum Clearance

Application

Specification

Metric

English

1st/2nd

0.35 mm

0.014 in

3rd/4th, 5th/6th, Reverse

0.84 mm

0.033 in