Transmission Clearance Specifications. Saturn RELAY Ext. 2006

GM Service Manual Online

For 1990-2009 cars only

Makes 🢒 Saturn 🢒 2006 🢒 RELAY Ext. 🢒 Transmission/Transaxle 🢒 Manual Transmission - Aisin AR5 🢒 Transmission Clearance Specifications

Table 1:	Gear Axial Clearance
Table 2:	Gear Radial Clearance
Table 3:	Output Shaft
Table 4:	Output 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	Maximum Clearance Metric	Standard Clearance English	Maximum Clearance English
1st Gear	0.20-0.45 mm	0.50 mm	0.0079-0.0177 in	0.0197 in
2nd Gear	0.10-0.25 mm	0.30 mm	0.0039-0.00098 in	0.0118 in
3rd Gear	0.10-0.25 mm	0.30 mm	0.0039-0.00098 in	0.0118 in
5th Countershaft Gear	0.10-0.35 mm	0.40 mm	0.0039-0.0138 in	0.0157 in

Gear Radial Clearance

Application	Standard Clearance Metric	Maximum Clearance Metric	Standard Clearance English	Maximum Clearance English
1st Gear	0.020-0.073 mm	0.160 mm	0.0008-0.0029 in	0.0063 in
2nd Gear	0.015-0.068 mm	0.160 mm	0.0006-0.0027 in	0.0063 in
3rd Gear	0.015-0.068 mm	0.160 mm	0.0006-0.0027 in	0.0063 in
5th Countershaft Gear	0.015-0.068 mm	0.160 mm	0.0006-0.0027 in	0.0063 in
Reverse Idler Gear	0.040-0.082 mm	0.130 mm	0.0016-0.0032 in	0.0051 in

Output Shaft

Application	Specification
Application	Metric	English
Runout - Maximum	0.06 mm	0.0024 in
Flange Thickness - Minimum	4.70 mm	0.1859 in

Output Shaft Bearing Journals - Minimum Diameter

Application	Specification
Application	Metric	English
1st Gear	38.860 mm	1.5299 in
2nd Gear	46.860 mm	1.8449 in
3rd Gear	37.860 mm	1.4905 in

Countershaft Bearing Journals - Minimum Diameter

Application	Specification
Application	Metric	English
5th Countershaft Gear Bearing	29.86 mm	1.1756 in

Synchronizer Blocker Ring to Gear - Minimum Clearance

Application	Specification
Application	Metric	English
1st Gear	0.8 mm	0.031 in
2nd Gear	0.8 mm	0.031 in
3rd Gear	0.8 mm	0.031 in
4th Gear	0.8 mm	0.031 in
5th Gear	0.8 mm	0.031 in

Synchronizer Sleeve to Shift Fork - Maximum Clearance

Application	Specification
Application	Metric	English
1st/2nd Gear	1.0 mm	0.039 in
3rd/4th Gear	1.0 mm	0.039 in
5th Gear	1.0 mm	0.039 in
Reverse Idler Gear	0.50 mm	0.0197 in