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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1473 (MANUAL TRANSMISSION - AISIN AY6)SPECIFICATIONSTRANSMISSION CLEARANCE SPECIFICATIONS
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Transmission Clearance Specifications

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Transmission Clearance Specifications
WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
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
RENDER: 1.0x

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.