AISIN AR-5 Manual Transmission Workshop Service Manual
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2007 TRANSMISSION
Manual Transmission - Aisin AR5 - H3
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
SEALERS, ADHESIVES AND LUBRICANTS
Sealers, Adhesives and Lubricants
LUBRICATION SPECIFICATIONS
Lubrication Specifications
Application
Specification
Metric English
Backup Lamp Switch 44 N.m 32 lb ft
Control Lever Boot Screw 2.5 N.m 22 lb in
Drain Plug 37 N.m 27 lb ft
Fill Plug 37 N.m 27 lb ft
Fuel Hose/Pipe Brackets Nut 20 N.m 15 lb ft
Input Shaft Bearing Retainer Bolt 17 N.m 13 lb ft
Shift Lever Assembly Bolt 20 N.m 15 lb ft
Transmission Mount Bolt 60 N.m 44 lb ft
Transmission Mount Nut 57 N.m 42 lb ft
Transmission Mounting Bolt 50 N.m 37 lb ft
Vehicle Speed Sensor (VSS) 17 N.m 13 lb ft
Application
Type of
Material
GM Part Number
United States Canada
Input Shaft Bearing Retainer Sealant 89020326 89021188
Input Shaft Bearing Retainer Bolts Pipe Sealant 12346004 10953480
Transmission Fluid 75W-90 Gear Oil 89021806 89021807
Application
Specification
Metric English
Manual Transmission Fluid
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
TRANSMISSION CLEARANCE SPECIFICATIONS
Gear Axial Clearance
Gear Radial Clearance
Output Shaft
Output Shaft Bearing Journals - Minimum Diameter
API AI-A or GL-3 SAE 75W-90
GM P/N 89021806 (Canadian P/N 89021807)
RWD: 2.2 liters
4WD: 2.3 liters
RWD: 2.3 quarts
4WD: 2.4 quarts
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
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
Application
Specification
Metric English
Runout - Maximum 0.06 mm 0.0024 in
Flange Thickness - Minimum 4.70 mm 0.1859 in
Specification
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
Countershaft Bearing Journals - Minimum Diameter
Synchronizer Blocker Ring to Gear - Minimum Clearance
Synchronizer Sleeve to Shift Fork - Maximum Clearance
1ST AND 2ND GEAR SYNCHRONIZER RETAINING RING SPECIFICATIONS
1st and 2nd Gear Synchronizer Retaining Ring Specifications
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
Application
Specification
Metric English
5th Countershaft Gear Bearing 29.86 mm 1.1756 in
Application
Specification
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
Application
Specification
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
Mark Thickness (mm) Thickness (in)
A 2.30-2.35 0.0906-0.0925
B 2.35-2.40 0.0925-0.0945
C 2.40-2.45 0.0945-0.0965
D 2.45-2.50 0.0965-0.0984
E 2.50-2.55 0.0984-0.1004
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
3RD AND 4TH GEAR SYNCHRONIZER RETAINING RING SPECIFICATIONS
3rd and 4th Gear Synchronizer Retaining Ring Specifications
5TH GEAR SYNCHRONIZER RETAINING RING SPECIFICATIONS
5th Gear Synchronizer Retaining Ring Specifications
COUNTERSHAFT FRONT BEARING RETAINING RING SPECIFICATIONS
Countershaft Front Bearing Retaining Ring Specifications
F 2.55-2.60 0.1004-0.1024
G 2.60-2.65 0.1024-0.1043
Mark Thickness (mm) Thickness (in)
A 1.80-1.85 0.0709-0.0728
B 1.85-1.90 0.0728-0.0748
C 1.90-1.95 0.0748-0.0768
D 1.95-2.00 0.0768-0.0787
E 2.00-2.05 0.0787-0.0807
F 2.05-2.10 0.0807-0.0827
G 2.10-2.15 0.0827-0.0846
Mark Thickness (mm) Thickness (in)
A 2.80-2.85 0.1102-0.1122
B 2.85-2.90 0.1122-0.1142
C 2.90-2.95 0.1142-0.1161
D 2.95-3.00 0.1161-0.1181
E 3.00-3.05 0.1181-0.1201
F 3.05-3.10 0.1201-0.1220
G 3.10-3.15 0.1220-0.1240
Mark Thickness (mm) Thickness (in)
A 2.05-2.10 0.0807-0.0827
B 2.10-2.15 0.0827-0.0846
C 2.15-2.20 0.0846-0.0866
D 2.20-2.25 0.0866-0.0886
E 2.25-2.30 0.0886-0.0906
F 2.30-2.35 0.0906-0.0925
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
INPUT SHAFT BEARING RETAINING RING SPECIFICATIONS
Input Shaft Bearing Retaining Ring Specifications
FIFTH GEAR RETAINING RING SPECIFICATIONS
Fifth Gear Retaining Ring Specifications
COMPONENT RESISTANCE
Component Resistance
Mark Thickness (mm) Thickness (in)
A 2.10-2.15 0.0827-0.0846
B 2.15-2.20 0.0846-0.0866
C 2.20-2.25 0.0866-0.0886
D 2.25-2.30 0.0886-0.0906
E 2.30-2.35 0.0906-0.0925
F 2.35-2.40 0.0925-0.0945
G 2.40-2.45 0.0945-0.0965
Mark Thickness (mm) Thickness (in)
C 2.75-2.80 0.1083-0.1102
D 2.80-2.85 0.1102-0.1122
E 2.85-2.90 0.1122-0.1142
F 2.90-2.95 0.1142-0.1161
G 2.95-3.00 0.1161-0.1181
H 3.00-3.05 0.1181-0.1201
J 3.05-3.10 0.1201-0.1220
K 3.10-3.15 0.1220-0.1240
L 3.15-3.20 0.1240-0.1260
M 3.20-3.25 0.1260-0.1280
N 3.25-3.30 0.1280-0.1299
P 3.30-3.35 0.1299-0.1319
Component
Pass Through
Pins
Resistance 25°
C (77°F)
Resistance 150°
C (302°F)
Resistance to
Ground (Case)
Vehicle Speed Sensor
1, 2
1,300-1,500
ohms
2,360-3,160
ohms
Greater than 10
M ohms
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
SCHEMATIC AND ROUTING DIAGRAMS
MANUAL TRANSMISSION SCHEMATIC ICONS
Manual Transmission Schematic Icons
MANUAL TRANSMISSION SCHEMATICS
Icon Icon Definition
NOTE:
The OBD II symbol is used on the circuit diagrams in
order to alert the technician that the circuit is essential
for proper OBD II emission control circuit operation. Any
circuit which fails and causes the malfunction indicator
lamp (MIL) to turn ON or causes emissions-related
component damage, is identified as an OBD II circuit.
Refer to Splicing Twisted or Shielded Cable .
IMPORTANT:
Twisted-pair wires provide an effective "shield" that helps
protect sensitive electronic components from electrical
interference. If the wires were covered with shielding,
install new shielding.
In order to prevent electrical interference from degrading
the performance of the connected components, you must
maintain the proper specification when making any
repairs to the twisted-pair wires shown :
The wires must be twisted a minimum of 9 turns per
31 cm (12 in) as measured anywhere along the
length of the wires.
The outside diameter of the twisted wires must not
exceed 6.0 mm (.25 in).
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
Fig. 1: Manual Transmission Schematic
Courtesy of GENERAL MOTORS CORP.
COMPONENT LOCATOR
MANUAL TRANSMISSION COMPONENT VIEWS
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
Fig. 2: Identifying Rear Engine Harness (MA5)
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 2
MANUAL TRANSMISSION CONNECTOR END VIEWS
Vehicle Speed Sensor (VSS)
Callout Component Name
1 Transmission Case
2 Backup Lamp Switch
3 Heated Oxygen Sensor (HO2S) 2
4 Transfer Case Encoder Motor Connector
5 Vehicle Speed Sensor (VSS) Connector
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
Fig. 3: Vehicle Speed Sensor (VSS) Connector End View
Courtesy of GENERAL MOTORS CORP.
Vehicle Speed Sensor (VSS) Connector Parts Information
Vehicle Speed Sensor (VSS) Connector Terminal Identification
Connector Part Information
OEM: 15359365
Service:
Description: 2-Way F GT 150 Series Sealed (BK)
Terminal Part Information
Terminal/Tray:
Core/Insulation Crimp:
Release Tool/Test Probe:
Pin Wire Color Circuit No. Function
1 PU 401 VSS Low Signal
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
VISUAL IDENTIFICATION
DISASSEMBLED VIEWS
Fig. 4: Transmission Cases Disassembled View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 4
2 YE 400 VSS High Signal
Callout Component Name
1 Input Shaft Seal
2 Transmission Front Case
6 Rear Bushing
2007 Hummer H3
2007 TRANSMISSION Manual Transmission - Aisin AR5 - H3
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Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$35.99
AISIN AR-5 MANUAL TRANSMISSION WORKSHOP SERVICE REPAIR MANUAL
This manual is compatible with the following computer operating systems:
- All Windows versions
- All Mac versions
You need the Adobe Acrobat Reader to view the document as the manual is in PDF format. If your computer doesn't have this application, you can download and install it for free from the Adobe Acrobat website.
File size: 11 MB
Transmission covered:
- 5-speed manual transmission AISIN AR-5
Contents:
- Service precaution
- General description
- Diagnosis
- Manual transmission assembly
- Transmission and associated parts
- Removal
- Installation
- Rear oil seal (transfer adapter) - Removal, Installation
- Transmission unit - Disassembled view, Disassembly, Inspection, Reassembly
- Diagnostic code index
- Shift lever assembly
- Transmission input shaft
- Transmission housing
- Bearing retainer replacement
- Control lever and/or boot replacement
- Transmission fluid replacement
- Diagrams
- Main data and specifications
- General specifications
- Torque specifications
- Special tools
This manual is presented for you in electronic format. You can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step-by-step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information and specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your gearbox working properly. It is this level of detail, along with illustrations, that guide the reader through each service, repair, and maintenance procedure.
