Manual Transmission
STANDARD SPECIFICATION
| Unit of length: mm (in) | ||||
|---|---|---|---|---|
| MEASUREMENT | STANDARD (NEW) | SERVICE LIMIT | ||
| Transmission oil | Capacity l (US qt. lmp qt) | 1.9 (2.0, 1.7) for overhaul | ||
| 1.8 (1.9, 1.6) for oil change | ||||
| Mainshaft | End play | 0.11 - 0.18 (0.004 - 0.007) | Adjust | |
| Diameter of ball bearing contact area A (Transmission housing side) | 21.987 - 22.000 (0.8656 - 0.8661) | 21.930 (0.8634) | ||
| Diameter of 4th, 5th gear contact area B | 26.980 - 26.993 (1.0622 - 1.0627) | 26.930 (1.0602) | ||
| Diameter of 3rd gear contact area C | 33.984 - 34.000 (1.3380 - 1.3386) | 33.930 (1.3358) | ||
| Diameter of ball bearing contact area D (Clutch housing side) | 25.977 - 25.990 (1.0227 - 1.0232) | 25.920 (1.0205) | ||
| Runout | 0.02 (0.001) max. | 0.05 (0.002) | ||
| Mainshaft 3rd and 4th gears | I.D. | 39.009 - 39.025 (1.5358 - 1.5364) | 39.07 (1.538) | |
| End play | 3rd | 0.06 - 0.21 (0.002 - 0.008) | 0.33 (0.013) | |
| 4th | 0.06 - 0.19 (0.002 - 0.007) | 0.31 (0.012) | ||
| Thickness | 3rd | 30.22 - 30.27 (1.190 - 1.192) | 30.15 (1.187) | |
| 4th | 30.12 - 30.17 (1.186 - 1.188) | 30.05 (1.183) | ||
| Mainshaft 5th gear | I.D. | 37.009 - 37.025 (1.4570 - 1.4577) | 37.07 (1.459) | |
| End play | 0.06 - 0.19 (0.002 - 0.007) | 0.31 (0.012) | ||
| Thickness | 28.42 - 28.47 (1.119 - 1.121) | 28.35 (1.116) | ||
| Countershaft | Diameter of needle bearing contact area A | 30.000 - 30.015 (1.1811 - 1.1817) | 29.950 (1.1791) | |
| Diameter of 1st gear contact area B | 35.984 - 36.000 (1.4167 - 1.4173) | 35.930 (1.4146) | ||
| Diameter of ball bearing contact area C | 24.980 - 24.993 (0.9835 - 0.9840) | 24.930 (0.9815) | ||
| Runout | 0.02 (0.001) max. | 0.05 (0.002) | ||
| Countershaft 1st gear | I.D. | 41.009 - 41.025 (1.6145 - 1.6152) | 41.07 (1.617) | |
| End play (When tightened by the specified torque) | 0.03 - 0.10 (0.001 - 0.004) | 0.22 (0.009) | ||
| Thickness | 30.41 - 30.44 (1.197 - 1.198) | 30.36 (1.195) | ||
| Countershaft 2nd gear | I.D. | 44.009 - 44.025 (1.7326 - 1.7333) | 44.07 (1.735) | |
| End play (When tightened by the specified torque) | 0.04 - 0.12 (0.002 - 0.005) | 0.24 (0.009) | ||
| Thickness | 31.92 - 31.97 (1257 - 1.259) | 31.85 (1.254) | ||
| Spacer collar (Countershaft 2nd gear) | I.D. | 32.988 - 32.998 (1.2987 - 1.2991) | 33.04 (1.301) | |
| O.D. | 38.989 - 39.000 (1.5350 - 1.5354) | 38.93 (1.533) | ||
| Length | 32.03 - 32.06 (1.261 - 1.262) | 32.01 (1.260) | ||
| Spacer collar (Mainshaft 4th and 5th gear) | ID. | 27.002 - 27.012 (1.0631 - 1.0635) | 27.06 (1.065) | |
| O.D. | 4th | 33.989 - 34.000 (1.3381 - 1.3386) | 33.93 (1.336) | |
| 5th | 31.989 - 32.000 (1.2594 - 1.2598) | 31.93 (1.257) | ||
| Length | 4th | 22.83 - 22.86 (0.899 - 0.900) | 22.81 (0.898) | |
| 5th | 23.53 - 23.56 (0.926 - 0.928) | 23.51 (0.926) | ||
| Reverse idler gear | I.D. | 15.016 - 15.043 (0.5912 - 0.5922) | 15.08 (0.594) | |
| Gear-to-reverse gear shaft clearance | 0.032 - 0.077 (0.0013 - 0.0030) | 0.14 (0.006) | ||
| Synchro ring | Ring-to-gear clearance (Ring pushed against gear) | 0.73 - 1.18 (0.029 - 0.046) | 0.4 (0.016) | |
| Shift fork | Fork finger thickness | 1st/2nd | 6.2 - 6.4 (0.244 - 0.252) | -- |
| 3rd/4th | 7.4 - 7.6 (0.291 - 0.299) | -- | ||
| Fork-to-synchro sleeve clearance | 0.35 - 0.65 (0.014 - 0.026) | 1.0 (0.04) | ||
| Reverse shift fork | Fork pawl groove width | 12.7 - 13.0 (0.50 - 0.51) | -- | |
| Fork-to-reverse idler gear clearance | 0.5 - 1.1 (0.020 - 0.043) | 1.8 (0.07) | ||
| L-groove width | 7.05 - 7.25 (0.278 - 0.285) | -- | ||
| Fork-to-5th/reverse shift piece pin clearance | 0.05 - 0.35 (0.002 - 0.014) | 0.5 (0.02) | ||
| Shift arm A | Inner diameter of shift arm C contact point | 13.005 - 13.130 (0.5120 - 0.5169) | -- | |
| Shift arm A-to-shift arm C clearance | 0.005 - 0.230 (0.0002 - 0.0091) | 0.35 (0.014) | ||
| Shift arm B | Inner diameter of shift arm B shaft contact point | 13.973 - 14.000 (0.5501 - 0.5512) | -- | |
| Shift arm B-to-shaft clearance | 0.013 - 0.070 (0.0005 - 0.0028) | 0.16 (0.006) | ||
| Shift arm B-to-shift piece clearance | 0.2 - 0.5 (0.008 - 0.020) | 0.62 (0.0244) | ||
| Diameter of shift piece contact point | 12.9 - 13.0 (0.508 - 0.512) | 12.78 (0.5031) | ||
| Final driven gear | Backlash | 0.07 - 0.130 (0.0028 - 0.0051) | 0.180 (0.0071) | |
| Differential carrier | Pinion shaft bore diameter | 18.010 - 18.028 (0.7091 - 0.7098) | -- | |
| Carrier-to-pinion shaft clearance | 0.023 - 0.057 (0.0009 - 0.0022) | 0.095 (0.004) | ||
| Driveshaft bore diameter | 26.025 - 26.045 (1.0246 - 1.0254) | -- | ||
| Carrier-to-driveshaft clearance | 0.045 - 0.086 (0.0018 - 0.0034) | 0.14 (0.006) | ||
| Differential pinion gear | Backlash | 0.05 - 0.15 (0.002 - 0.006) | -- | |
| Pinion gear bore diameter | 18.042 - 18.066 (0.7103 - 0.7113) | -- | ||
| Pinion gear-to-pinion shaft clearance | 0.055 - 0.095 (0.0021 - 0.0037) | 0.15 (0.006) | ||
| Set ring-to-bearing outer race | 0 - 0.1 (0 - 0.004) | Adjust with shim | ||