BRP Johnson 4HP User manual

FOREWORD
GROUP INDEX
FOREWORD
This manual contains an introductory description
on Johnson®4/5/6 HP outboard motors and pro-
cedures for the inspection, service and overhaul
of its main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION
section to familiarize yourself with basic
information concerning this motor. Read and
refer to the other sections in this manual for
information regarding proper inspection and
service procedures.
This manual will help you better understand this
outboard motor so that you may provide your
customers with optimum and quick service.
•This manual has been prepared using the lat-
est information available at the time of publica-
tion. If a modification has been made since
then, differences may exist between the con-
tent of this manual and the actual outboard
motor.
•Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures and may not represent the actual out-
board motor in exact detail.
•This manual is intended for use by technicians
who already possess the basic knowledge and
skills to service Johnson outboard motors.
Persons without such knowledge and skills
should not attempt to service an outboard engine
by relying on this manual only.
Instead, please contact your nearby authorized
Johnson outboard motor dealer.
Apprentice or do-it-yourself mechanics that
do not have the proper tools and equipment
may not be able to properly perform the ser-
vices described in this manual.
Improper repair may result in injury to the
mechanic and may render the engine unsafe
for the boat operator and passengers.
GROUP INDEX
FOREWORD
GENERAL INFORMATION .................... 1–1
PERIODIC MAINTENANCE ................... 2–1
IGNITION AND ELECTRICAL ................ 3–1
FUEL SYSTEM ....................................... 4–1
RECOIL STARTER ................................. 5–1
POWER UNIT ......................................... 6–1
MID UNIT ................................................ 7–1
LOWER UNIT ......................................... 8–1
WIRE / HOSE ROUTING ........................ 9–1
SAFETY .................................................. S–1
Printed in the United States
© 2006 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

FOREWORD
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
To Locate What You Are Looking For:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page
in a GROUP INDEX. Select the section needed for
reference.
3. Find topics easily by using the running headings at
the upper outside corners of each page. The primary
running heading is the section; the secondary running
heading is the subsection.
4. The first page of each section lists a table of contents to easily locate the item and page you need.
Component Parts and Important Item Illustrations
Under the name of each system or unit, an exploded view is provided with work instructions and other
service information such as the tightening torque, lubrication and locking agent points.
Example:
POWER UNIT
INSTALLATION
INSTALLATION
Installation is reverse order of removal with special attention
to the following steps.
Do not re-use gasket removed. Be sure to use new gas-
ket.
INSTALLATION
Install:
Power unit
W Moly Lube
Note:
• Apply Moly Lube to drive shaft splines.
• Rotate the crankshaft to aid alignment of driveshaft
and crankshaft splines.
Primary and secondary
running headings
10 N·m (1.0 kg-m; 7.0 lb-ft)
50 N·m (5.0 kg-m; 36.0 lb-ft)
Crankshaft
1Nut (1)
2Key (1)
3Flywheel (1)
4CDI & coil unit (1)
5Spark plug cap (1)
6Bolt (2)
NOTE:
Clean the flywheel and crankshaft
mating surfaces with cleaning solvent.

FOREWORD
SYMBOLS
SYMBOLS
Listed in the table below are the symbols indicating instructions and other important information neces-
sary for proper servicing. Please note the definition for each symbol. You will find these symbols used
throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required. Data beside
it indicates specified torque. Apply NUT LOCK™.
Apply oil. Use engine oil unless
otherwise specified. Apply ULTRA LOCK™.
Apply HPF XR™ Gearcase
Lubricant. Measure in DC voltage range.
Apply MOLY LUBE™. Measure in resistance range.
Apply TRIPLE-GUARD®Grease. Measure in continuity test range.
Apply THREE BOND “1104”. Use peak voltmeter “Stevens CD-77”.
Apply THREE BOND “1207B”. Use special tool.
Apply SILICONE SEAL.

1-1
GENERAL INFORMATION
CONTENTS
GENERAL INFORMATION
CONTENTS
WARNING / CAUTION / NOTE ................................................................................................................ 1-2
GENERAL PRECAUTIONS ..................................................................................................................... 1-2
IDENTIFICATION NUMBER LOCATION ................................................................................................. 1-4
MODEL, PRE-FIX, SERIAL NUMBER ....................................................................................................... 1-4
ENGINE SERIAL NUMBER ..................................................................................................................... 1-4
FUEL AND OIL ......................................................................................................................................... 1-4
GASOLINE RECOMMENDATION ............................................................................................................ 1-4
ENGINE OIL ......................................................................................................................................... 1-4
ENGINE BREAK-IN .................................................................................................................................. 1-5
WARM-UP RECOMMENDATION ............................................................................................................. 1-5
THROTTLE RECOMMENDATION ............................................................................................................ 1-5
PROPELLERS .......................................................................................................................................... 1-6
SPECIFICATIONS .................................................................................................................................... 1-7
TIGHTENING TORQUE .......................................................................................................................... 1-15
SPECIAL TOOLS ................................................................................................................................... 1-17
NOTES .................................................................................................................................................... 1-20

1-2
GENERAL INFORMATION
WARNING / CAUTION / NOTE
WARNING / CAUTION / NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the sym-
bol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the
messages highlighted by these signal words.
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motor damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical
safety principles.
GENERAL PRECAUTIONS
•Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the outboard motor.
•To avoid eye injury, always wear protective goggles when filing metals, working on a grinder,
or doing other work, which could cause flying material particles.
•When 2 or more persons work together, pay attention to the safety of each other.
•When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
•When testing an outboard motor in the water and on a boat, ensure that the necessary safety
equipment is on board. Such equipment includes: flotation aids for each person, fire extin-
guisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope,
etc.
•When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
•Never use gasoline as a cleaning solvent.
•To avoid getting burned, do not touch the engine, engine oil or exhaust system during or
shortly after engine operation.
•Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and
used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve
shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil con-
tacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with
oil. Recycle or properly dispose of used oil.
•After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fittings
related to the system for leaks.
•Carefully adhere to the battery handling instructions laid out by the battery supplier.

1-3
GENERAL INFORMATION
GENERAL PRECAUTIONS
•If parts replacement is necessary, replace the parts with Evinrude/Johnson Genuine Parts or
their equivalent.
•When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
•Be sure to use special tools when instructed.
•Make sure that all parts used in assembly are clean and also lubricated when specified.
•When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the speci-
fied type.
•When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
•When performing service to electrical parts, if the service procedures do not require using bat-
tery power, disconnect the negative cable at the battery.
•Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with
smaller diameter. Always tighten from inside to outside diagonally to the specified tightening
torque.
•Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cot-
ter pins, circlips, and certain other parts as specified, always replace them with new. Also,
before installing these new parts, be sure to remove any left over material from the mating sur-
faces.
•Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
•Use a torque wrench to tighten fasteners to the torque values when specified. Remove grease
or oil from screw / bolt threads unless a lubricant is specified.
•After assembly, check parts for tightness and operation.
•To protect the environment, do not unlawfully dispose of used motor oil, other fluids, and bat-
teries.
•To protect the Earth’s natural resources, properly dispose of used motor parts.

1-4
GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
IDENTIFICATION NUMBER LOCATION
Model, Prefix, Serial Number
The MODEL, PREFIX and SERIAL NUMBER of the motor
are stamped on a plate attached to the clamp bracket.
Example
Engine Serial Number
A second engine serial number plate is pressed into a boss
on the cylinder block.
FUEL AND OIL
Gasoline Recommendation
Johnson highly recommends that you use alcohol-free
unleaded gasoline with a minimum pump octane rating of 87
(R+M / 2 method) or 91 (Research method). However,
blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
Allowable maximum blend of a single additive (not combina-
tion): 5% Methanol, 10% Ethanol, 15% MTBE
If leaded gasoline is used, engine damage may result.
Use only unleaded gasoline.
Engine Oil
Use only Evinrude/Johnson Ultra™Four Stroke Oil or oils
that are rated SE, SF, SG, SH, or SJ under the API (Ameri-
can Petroleum Institute) classification system.
The viscosity rating should be SAE 10W-40.
If an SAE 10W-40 motor oil is not available, select an alter-
native according to the chart at right.
BREAK-IN (First 10 Hours)
Use only Evinrude/Johnson Four Stroke Oil or SAE 10W-40,
API SE, SF, SG, SH, or SJ rating.
ENGINE OIL
Temperature
Typical placement example

1-5
GENERAL INFORMATION
ENGINE BREAK-IN
ENGINE BREAK-IN
The first 10 hours are critically important to ensure correct
running of either a brand new motor or a motor that has been
reconditioned or rebuilt. How the motor is operated during
this time will have direct bearing on its life span and long-
term durability.
Break-in period: 10 hours
Warm-Up Recommendation
Allow sufficient idling time (more than 5 minutes) for the
engine to warm up after cold engine starting.
Throttle Recommendation
NOTE:
Avoid maintaining a constant engine speed for an extended
period at any time during the engine break-in by varying the
throttle position occasionally.
1. FIRST 2 HOURS
For first 15 minutes, operate the engine in-gear at idling
speed.
During the remaining 1 hour and 45 minutes, operate the
engine in-gear at less than 1/2 (half) throttle (3000 r/min).
NOTE:
The throttle may be briefly opened beyond the recommended
setting to plane the boat, but must be reduced to the recom-
mended setting immediately after planing.
2. NEXT 1 HOUR
Operate the engine in-gear at less than 3/4 (three-quar-
ter) throttle (4000 r/min).
3. LAST 7 HOURS
Operate the engine in-gear at desired engine speed.
However, do not operate continuously at full throttle for
more than 5 minutes.

1-6
GENERAL INFORMATION
PROPELLERS
PROPELLERS
An outboard motor is designed to develop its rated power
within a specified engine speed range. The maximum rated
power delivered is shown below.
If the standard propeller fails to meet the above requirement,
use another pitch propeller to hold the engine speed within
the range specified above.
Propeller selection chart
Installing a propeller with pitch either too high or too low
will cause incorrect maximum engine speed, which may
result in severe damage to the motor.
Recommended full
throttle speed range
4 HP, 4000 – 5000 r/min
5 HP, 4500 – 5500 r/min
6 HP, 4750 – 5750 r/min
Blade × Diam. (in) × Pitch (in)
3 × 7 1/2 × 6
3 × 7 1/2 × 6 1/2
3 × 7 1/2 × 7

1-7
GENERAL INFORMATION
*SPECIFICATIONS
*SPECIFICATIONS
*These specifications are subject to change without notice.
Item Unit Data
4 HP 5 HP 6 HP
DIMENSIONS AND WEIGHT
Overall length (front to back) mm (in) 554 (21.8): with tiller handle raised
Overall width (side to side) mm (in) 309 (12.2)
Overall height S mm (in) 1064 (41.9)
L mm (in) 1191 (46.9)
Weight
(without engine oil) S kg (Ib) 26 (55.1)
L kg (Ib) 27 (57.3)
Transom height S mm (inch type) 442 (15)
L mm (inch type) 569 (20)
PERFORMANCE
Maximum output kW (PS) 2.9 (4) 3.7 (5) 4.4 (6)
Recommended operating range r/min 4000 – 5000 4500 – 5500 4750 – 5750
Idle speed r/min 1300 ± 50
(in-gear: approx: 1150) 1300 ± 50 (in-gear: approx: 1200)
POWERHEAD
Engine type 4-stroke OHV
Number of cylinders 1
Bore mm (in) 62.0 (2.44)
Stroke mm (in) 46.0 (1.81)
Total displacement cm3(cu in) 138 (8.4)
Compression ratio : 1 9.2
Spark plug NGK BPR6ES
Ignition system Electronic Ignition (Digital CDI)
Fuel supply system Carburetor
Exhaust system Above prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual
Choke system Manual
Throttle control Twist grip

1-8
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
4 HP 5 HP 6 HP
FUEL AND OIL
Fuel Johnson highly recommends that you use alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 (R+M/2 method) or 91 (Research
method). However, blends of unleaded gasoline and alcohol with equivalent
octane content may be used.
Fuel tank capacity (Built-in tank) l (US/Imp. gal) 1.5 (0.40/0.33)
Engine oil Ultra Four Stroke Oil
or Viscosity rating 10W-40, API classification SE, SF, SG, SH, SJ
BREAK-IN OIL (FIRST 10 HOURS) Evinrude/Johnson Four Stroke Oil
Engine oil amounts l (US/Imp. qt) 0.7 (0.74/0.62)
Gear oil HPF XR Gearcase Lubricant
Gearcase oil amounts ml (US/Imp. oz) 190 (6.4/6.7)
BRACKET
Trim angle 4° – 20° (Shallow drive angle: 32°, 45°)
Number of tilt pin position Adjustable 5
Maximum tilt angle degree 71° (from lowest tilt pin position)
GEARCASE
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12:23 (1.92)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in) × Pitch (in)
3 × 7 1/2 × 6
3 × 7 1/2 × 6 1/2
3 × 7 1/2 × 7

1-9
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
4 HP 5 HP 6 HP
POWERHEAD
Recommended operating range r/min 4000 – 5000 4500 – 5500 4750 – 5750
Idle speed r/min 1300 ± 50
(in-gear: approx: 1150) 1300 ± 50 (in-gear: approx: 1200)
*Cylinder compression
(with decompression system) kPa (kg/cm2, psi) 550 – 650 (5.5 – 6.5; 78 – 92)
Engine oil Ultra Four Stroke Oil
or Viscosity rating 10W-40, API classification SE, SF, SG, SH, SJ
BREAK-IN OIL
(FIRST 10 HOURS) Evinrude/Johnson Four Stroke Oil
Engine oil amounts l (US/Imp. qt) 0.7 (0.74/0.62)
Thermostat operating temperature °C (°F) 48 – 52 (118 – 126)
* Figures shown are guidelines only, not absolute service limits.
CARBURETOR
Type KEIHIN BC19-3.5 KEIHIN BC19-3.5 KEIHIN BC21-15
I.D mark 91J80 91J90 91JB0
Main jet # 70 78
Pilot jet # 35 38
Pilot screw Turns open PRE-SET
Float height mm 10 ± 1

1-10
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
4 HP 5 HP 6 HP
CYLINDER HEAD/CAMSHAFT
Cylinder head distortion Limit mm (in) 0.05 (0.002)
Cam height IN STD mm (in) 32.401 – 32.461 (1.2756 – 1.2780)
Limit mm (in) 32.101 (1.2638)
EX STD mm (in) 32.538 – 32.598 (1.2810 – 1.2834)
Limit mm (in) 32.238 (1.2692)
Camshaft journal oil clearance Upper STD mm (in) 0.016 – 0.062 (0.0006 – 0.0024)
Limit mm (in) 0.150 (0.0059)
Lower STD mm (in) 0.016 – 0.052 (0.0006 – 0.0020)
Limit mm (in) 0.150 (0.0059)
Camshaft holder inside diameter Upper STD mm (in) 15.000 – 15.028 (0.5906 – 0.5917)
Lower STD mm (in) 16.000 – 16.018 (0.6299 – 0.6306)
Camshaft journal outside diameter Upper STD mm (in) 14.966 – 14.984 (0.5892 – 0.5899)
Lower STD mm (in) 15.966 – 15.984 (0.6286 – 0.6293)

1-11
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
VALVE/VALVE GUIDE
Valve diameter IN mm (in) 24.0 (0.94)
EX mm (in) 22.0 (0.87)
Valve clearance (Cold engine
condition) IN STD mm (in) 0.03 – 0.07 (0.001 – 0.003)
EX STD mm (in) 0.03 – 0.07 (0.001 – 0.003)
Valve seat angle IN — 15°, 45°
EX — 15°, 45°
Valve guide to valve stem
clearance IN STD mm (in) 0.025 – 0.052 (0.0010 – 0.0020)
Limit mm (in) 0.075 (0.0030)
EX STD mm (in) 0.045 – 0.072 (0.0018 – 0.0028)
Limit mm (in) 0.090 (0.0035)
Valve guide inside diameter IN,EX STD mm (in) 5.500 – 5.512 (0.2165 – 0.2170)
Valve guide protrusion IN,EX STD mm (in) 11.0 (0.43)
Valve stem outside diameter IN STD mm (in) 5.460 – 5.475 (0.2150 – 0.2156)
EX STD mm (in) 5.440 – 5.455 (0.2142 – 0.2148)
Valve stem deflection IN,EX Limit mm (in) 0.35 (0.014)
Valve stem runout IN,EX Limit mm (in) 0.05 (0.002)
Valve head radial runout IN,EX Limit mm (in) 0.08 (0.003)
Valve head thickness IN,EX STD mm (in) 1.0 (0.04)
Limit mm (in) 0.5 (0.02)
Valve seat contact width IN STD mm (in) 0.8 – 1.0 (0.03 – 0.04)
EX STD mm (in) 1.0 – 1.2 (0.04 – 0.05)
Valve spring free length STD mm (in) 29.5 (1.16)
Limit mm (in) 28.3 (1.11)
Valve spring tension STD N (kg, Ib) 139 – 159 (13.9 – 15.9, 30.6 – 35.1) for 19.3 mm (0.76 in)
Limit N (kg, Ib) 127 (12.7, 28.0) for 19.3 mm (0.76 in)

1-12
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
CYLINDER/PISTON/PISTON RING
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder clearance STD mm (in) 0.010 – 0.040 (0.0004 – 0.0016)
Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 62.000 – 62.015 (2.4409 – 2.4415)
Cylinder measuring position mm (in) 35 (1.4) from cylinder top surface
Piston skirt diameter STD mm (in) 61.975 – 61.990 (2.4400 – 2.4406)
Piston measuring position mm (in) 14 (0.6) from piston skirt end
Cylinder bore wear Limit mm (in) 0.100 (0.0039)
Piston ring end gap 1st STD mm (in) 0.20 – 0.35 (0.008 – 0.014)
Limit mm (in) 0.70 (.028)
2nd STD mm (in) 0.35 – 0.50 (0.014 – 0.020)
Limit mm (in) 1.00 (0.039)
Piston ring free end gap 1st, 2nd STD mm (in) Approx. 8.5 (0.33)
Limit mm (in) 6.8 (0.27)
Piston ring to groove
clearance 1st, 2nd STD mm (in) 0.03 – 0.07 (0.001 – 0.003)
Limit mm (in) 0.12 (0.005)
Piston ring groove width 1st, 2nd STD mm (in) 1.22 – 1.24 (0.048 – 0.049)
Oil STD mm (in) 2.51 – 2.53 (0.099 – 0.100)
Piston ring thickness 1st, 2nd STD mm (in) 1.17 – 1.19 (0.046 – 0.047)
Pin clearance in piston pin hole STD mm (in) 0.006 – 0.019 (0.0002 – 0.0007)
Limit mm (in) 0.040 (0.0016)
Piston pin outside diameter STD mm (in) 17.995 – 18.000 (0.7085 – 0.7087)
Limit mm (in) 17.980 (0.7079)
Piston pin hole diameter STD mm (in) 18.006 – 18.014 (0.7089 – 0.7092)
Limit mm (in) 18.030 (0.7098)
Pin clearance in conrod small end STD mm (in) 0.006 – 0.019 (0.0002 – 0.0007)
Limit mm (in) 0.050 (0.0020)

1-13
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
CRANKSHAFT / CONROD
Conrod small end inside diameter STD mm (in) 18.006 – 18.014 (0.7089 – 0.7092)
Limit mm (in) 18.040 (0.7102)
Conrod big end oil clearance STD mm (in) 0.015 – 0.035 (0.0006 – 0.0014)
Limit mm (in) 0.080 (0.0031)
Conrod big end inside diameter STD mm (in) 28.015 – 28.025 (1.1030 – 1.1033)
Crank pin outside diameter STD mm (in) 27.990 – 28.000 (1.1020 – 1.1024)
Crank pin outside diameter difference
(out-of-round and taper) Limit mm (in) 0.010 (0.0004)
Conrod big end side clearance STD mm (in) 0.20 – 0.90 (0.008 – 0.0035)
Limit mm (in) 1.20 (0.047)
Conrod big end width STD mm (in) 23.30 – 23.80 (0.917 – 0.937)
Crank pin width STD mm (in) 24.00 – 24.20 (0.945 – 0.953)
Crankshaft runout Limit mm (in) 0.05 (0.002)
Crankshaft lower journal oil clearance STD mm (in) 0.020 – 0.062 (0.0008 – 0.0024)
Limit mm (in) 0.100 (0.0039)
Crankcase lower holder inside diameter STD mm (in) 25.000 – 25.021 (0.9843 – 0.9851)
Crankshaft lower journal outside
diameter STD mm (in) 24.959 – 24.980 (0.9826 – 0.9835)

1-14
GENERAL INFORMATION
*SPECIFICATIONS
Item Unit Data
4 HP 5 HP 6 HP
ELECTRICAL
Ignition timing Degrees BTDC 3° – 28°
Over revolution limiter r/min 6000
Ignition coil resistance Secondary kΩat 20°C 8.4 – 12.4 [H.T.cord – pulser core]
Spark plug cap resistance kΩat 20°C 7.5 – 12.5
Battery charge coil resistance (Optional part) Ωat 20°C 0.6 – 1.0 [R – Y]
Battery charge coil output (12V) (Optional part) AMP 6-7
Standard spark plug Type NGK BPR6ES
Gap mm (in) 0.7 – 0.8 (0.028 – 0.031)
GEARCASE
Design specification thickness for shim and washer
Pinion gear backup shim mm (in) 2.0 (0.08)
Forward gear backup shim mm (in) 1.2 (0.05)
Forward gear thrust washer mm (in) 1.0 (0.04)
Reverse gear thrust washer mm (in) 1.0 (0.04)
Reverse gear backup shim mm (in) 0.8 (0.03)
Initial selection-shim adjustment may be required.