On my Japanese cars, 95% of repairs can be made with 5 sizes of sockets / wrenches (8, 10, 12, 14, 17mm). I was surprised when doing a simple repair on my BMW that I seemingly needed every metric tool in my tool box. (Apparently this has something to do with the Japanese vs German Standards for bolts). For Japanese cars, I carry a very small toolkit in the car (or I take it to the Pick ‘N Pull junkyard) and know that I can perform every possible repair with that small kit.
When I recently replaced the engine and trans in my Sprinter, I was careful to note which hand tools sizes were needed. These are the sockets / wrenches I used. My intent was to determine which sizes to carry with me, however it seems it may be easier to take everything as the list is quite extensive. I hope others find this useful.
6 point:
6mm (hose clamps mostly)
7mm (hose clamps exclusively)
8mm (hose clamps mostly)
10mm
11mm (but this was the license plate only, so I am guessing these were not the original bolts as 11mm was not used anywhere else)
13mm
15mm (trans to driveshaft only)
16mm
17mm
18mm (motor mount)
18.5mm (one fitting on the power steering line for the rack was too large for 18, but 19 was loose – I used a 19mm to remove it – note that this is an open end or flare wrench, not a socket)
19mm
22mm (power steering rack fitting – open end or flare wrench)
27mm (crank bolt)
12 point socket: I needed something largish for the serpentine belt tensioner and a 6 point won’t work – I’ll double check the size and edit this post.
Regular torx:
T15
T25
T30
T45
T47 (this one is important – it seems someone tried a T45 in one of these and stripped it and I had to remove it with vice grips)
External torx:
E8 (sheet metal bracket on rear of trans mount only)
E10
E12
E14
Hex (Allen key):
5mm (injector cover, trans drain pan, I think this is also the same size for the torque converter)
6mm (oil pressure sender plug behind AC compressor)
When I recently replaced the engine and trans in my Sprinter, I was careful to note which hand tools sizes were needed. These are the sockets / wrenches I used. My intent was to determine which sizes to carry with me, however it seems it may be easier to take everything as the list is quite extensive. I hope others find this useful.
6 point:
6mm (hose clamps mostly)
7mm (hose clamps exclusively)
8mm (hose clamps mostly)
10mm
11mm (but this was the license plate only, so I am guessing these were not the original bolts as 11mm was not used anywhere else)
13mm
15mm (trans to driveshaft only)
16mm
17mm
18mm (motor mount)
18.5mm (one fitting on the power steering line for the rack was too large for 18, but 19 was loose – I used a 19mm to remove it – note that this is an open end or flare wrench, not a socket)
19mm
22mm (power steering rack fitting – open end or flare wrench)
27mm (crank bolt)
12 point socket: I needed something largish for the serpentine belt tensioner and a 6 point won’t work – I’ll double check the size and edit this post.
Regular torx:
T15
T25
T30
T45
T47 (this one is important – it seems someone tried a T45 in one of these and stripped it and I had to remove it with vice grips)
External torx:
E8 (sheet metal bracket on rear of trans mount only)
E10
E12
E14
Hex (Allen key):
5mm (injector cover, trans drain pan, I think this is also the same size for the torque converter)
6mm (oil pressure sender plug behind AC compressor)