Manual Transmission And M/T Differential
MANUAL TRANSMISSION AND M/T DIFFERENTIAL (STANDARDS AND SERVICE LIMITS)
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Transmission fluid | Capacity | Fluid change | 1.5 L (1.59 US qt) | |
| Use Honda MTF | Overhaul | 1.6 L (1.69 US qt) | ||
| Mainshaft | End play | 0.11 - 0.18 mm (0.004-0.007 in.) | Adjust | |
| Diameter of ball bearing contact area (Transmission housing side) | 25.987-26.000 mm (1.0231-1.0236 in.) | 25.93 mm (1.021 in.) | ||
| Diameter of spacer collar contact area | 28.992-29.005 mm (1.1414-1.1419 in.) | 28.93 mm (1.139 in.) | ||
| Diameter of needle bearing contact area | 34.984-35.000 mm (1.3773-1.3780 in.) | 34.93 mm (1.375 in.) | ||
| Diameter of ball bearing contact area (Clutch housing side) | 25.977-25.990 mm (1.0223-1.0232 in.) | 25.92 mm (1.020 in.) | ||
| Runout | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | ||
| Mainshaft 3rd gear | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | - | |
| End play | 0.06-0.21 mm (0.002-0.008 in.) | 0.33 mm (0.01 in.) | ||
| Thickness | 27.92-27.97 mm (1.099-1.101 in.) | 27.85 mm (1.096 in.) | ||
| Mainshaft 4th gear | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | - | |
| End play | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.01 in.) | ||
| Thickness | 27.02-27.07 mm (1.064-1.066 in.) | 26.95 mm (1.061 in.) | ||
| Mainshaft 5th gear | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | - | |
| End play | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.01 in.) | ||
| Thickness | 28.92-28.97 mm (1.139-1.141 in.) | 28.85 mm (1.136 in.) | ||
| Mainshaft 4th and 5th gears spacer collar | I.D. | 29.014-29.024 mm (1.1423-1.1427 in.) | 29.06 mm (1.144 in.) | |
| O.D. | 34.989-35.000 mm (1.3775-1.3780 in.) | 34.93 mm (1.375 in.) | ||
| Length | A | 51.97-52.03 mm (2.046-2.048 in.) | - | |
| B | 24.03-24.06 mm (0.946-0.947 in.) | 24.01 mm (0.945 in.) | ||
| Countershaft | Diameter of ball bearing contact area | 24.980-24.993 mm (0.9835-0.9840 in.) | 24.93 mm (0.981 in.) | |
| Diameter of ball bearing contact area (Transmission housing side) | 37.984-38.000 mm (1.4954-1.4961 in.) | 37.934 mm (1.4935 in.) | ||
| Diameter of ball bearing contact area (Clutch housing side) | 34.000-34.015 mm (1.3386-1.3392 in.) | 33.95 mm (1.337 in.) | ||
| Runout | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | ||
| Countershaft 1st gear | I.D. | 43.009-43.025 mm (1.6933-1.6939 in.) | 43.07 mm (1.696 in.) | |
| End play | 0.03-0.10 mm (0.001-0.004 in.) | 0.22 mm (0.009 in.) | ||
| Thickness | 26.91-26.94 mm (1.059-1.061 in.) | 26.86 mm (1.057 in.) | ||
| Countershaft 2nd gear | I.D. | 45.009-45.025 mm (1.7720-1.7726 in.) | 45.07 mm (1.774 in.) | |
| End play | 0.04-0.12 mm (0.002-0.005 in.) | 0.24 mm (0.009 in.) | ||
| Thickness | 27.41-27.46 mm (1.079-1.081 in.) | 27.36 mm (1.077 in.) | ||
| Countershaft 2nd gear spacer collar | I.D. | 34.000-34.010 mm (1.3386-1.3390 in.) | 34.04 mm (1.340 in.) | |
| O.D. | 39.989-40.000 mm (1.5744-1.5748 in.) | 39.93 mm (1.572 in.) | ||
| Thickness | 27.53-27.56 mm (1.084-1.085 in.) | 27.51 mm (1.083 in.) | ||
| Shift arm | Shift arm-to-shift fork clearance | 0.2-0.5 mm (0.008-0.020 in.) | 0.62 mm (0.024 in.) | |
| Finger width | 12.9-13.0 mm (0.508-0.512 in.) | - | ||
| I.D. | 13.973-14.000 mm (0.5501-0.5512 in.) | - | ||
| Shift lever | Shaft-to-select lever clearance | 0.05-0.40 mm (0.002-0.016 in.) | 0.6 mm (0.024 in.) | |
| Groove (to select lever) | 15.00-15.15 mm (0.591-0.596 in.) | - | ||
| Shaft-to-shift arm clearance | 0.013-0.070 mm (0.0005-0.0028 in.) | 0.1 mm (0.004 in.) | ||
| Select lever | Finger width | 14.75-14.95 mm (0.581-0.589 in.) | 14.45 mm (0.569 in.) | |
| Reverse shift fork | Fork-to-reverse idler gear clearance | 0.1-0.5 mm (0.004-0.020 in.) | 0.8 mm (0.03 in.) | |
| Finger width | 15.8-16.0 mm (0.62-0.63 in.) | 15.5 mm (0.61 in.) | ||
| Reverse idler gear | Groove (to reverse shift fork) | 16.1-16.3 mm (0.63-0.64 in.) | 16.5 mm (0.65 in.) | |
| I.D. | 15.016-15.043 mm (0.5912-0.5922 in.) | 15.08 mm (0.594 in.) | ||
| Shift fork | Fork-to-synchro sleeve clearance | 0.35-0.65 mm (0.014-0.026 in.) | 1.00 mm (0.039 in.) | |
| Finger thickness | 1-2 shift fork | 6.7-6.9 mm (0.26-0.27 in.) | - | |
| 3-4, 5th shift forks | 6.2-6.4 mm (0.24-0.25 in.) | - | ||
| Groove (to shift arm) | 1-2 shift piece | 13.2-13.4 mm (0.52-0.53 in.) | - | |
| 3-4 shift piece | Groove (to shift arm) | 13.2-13.4 mm (0.52-0.53 in.) | - | |
| 5-R shift piece | Groove (to shift arm) | 13.2-13.4 mm (0.52-0.53 in.) | - | |
| Synchro ring | Ring-to-gear clearance | Ring pushed against gear | 0.85-1.10 mm (0.033-0.043 in.) | 0.4 mm (0.016 in.) |
| Double cone synchro | Outer synchro ring-to-synchro cone clearance | Ring pushed against gear | 0.5-1.0 mm (0.02-0.04 in.) | 0.3 mm (0.01 in.) |
| Synchro cone-to-gear clearance | Ring pushed against gear | 0.5-1.0 mm (0.02-0.04 in.) | 0.3 mm (0.01 in.) | |
| Outer synchro ring-to-gear clearance | Ring pushed against gear | 0.95-1.68 mm (0.037-0.066 in.) | 0.6 mm (0.02 in.) | |
| M/T differential carrier | Carrier-to-pinion shaft clearance | 0.026-0.062 mm (0.0010-0.0024 in.) | 0.95 mm (0.037 in.) | |
| Pinion shaft bore diameter | 15.010-15.028 mm (0.5909-0.5917 in.) | - | ||
| Carrier-to-driveshaft clearance | 0.045-0.086 mm (0.0018-0.0034 in.) | 0.14 mm (0.006 in.) | ||
| Driveshaft bore diameter | 26.025-26.045 mm (1.0246-1.0254 in.) | - | ||
| M/T differential pinion gear | Backlash | 0.05-0.15 mm (0.002-0.006 in.) | - | |
| Pinion gear-to-pinion shaft clearance | 0.058-1.000 mm (0.0023-0.0394 in.) | 0.15 mm (0.006 in.) | ||
| Pinion shaft bore diameter | 15.042-15.066 mm (0.5922-0.5931 in.) | - | ||
| 72 mm shim | Set ring-to-bearing outer race clearance | 0-0.1 mm (0-0.004 in.) | Adjust | |