Manual Transmission
MANUAL TRANSMISSION STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Transmission fluid | Capacity Use Honda MTF |
Fluid change | 1.48 L (1.56 US qt) | |
| Overhaul | 1.62 L (1.71 US qt) | |||
| Mainshaft | End play | - | 0.14-0.21 mm (0.006-0.008 in.) | Adjust |
| Diameter of transmission housing ball bearing contact area | - | 27.987-28.000 mm (1.1018-1.1024 in.) | 27.94 mm (1.100 in.) | |
| Diameter of 4th/5th gears contact area | - | 34.987-35.000 mm (1.3774-1.3780 in.) | 34.94 mm (1.376 in.) | |
| Diameter of 6th gear contact area | - | 38.984-39.000 mm (1.5348-1.5354 in.) | 38.94 mm (1.533 in.) | |
| Diameter of clutch housing ball bearing contact area | - | 28.002-28.015 mm (1.1024-1.1030 in.) | 27.95 mm (1.100 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Mainshaft 3rd gear | I.D. | - | 40.009-40.025 mm (1.5752-1.5758 in.) | - |
| Thickness | - | 35.09-35.17 mm (1.381-1.385 in.) | 34.97 mm (1.377 in.) | |
| End play | - | 0.06-0.19 mm (0.002-0.007 in.) | 0.3 mm (0.012 in.) | |
| Mainshaft 3rd gear distance collar | I.D. | - | 28.002-28.012 mm (1.1024-1.1028 in.) | - |
| O.D. | - | 34.989-35.000 mm (1.3775-1.3780 in.) | - | |
| Length | - | 35.23-35.28 mm (1.387-1.389 in.) | - | |
| Mainshaft 4th and 5th gears | I.D. | - | 47.009-47.025 mm (1.8507-1.8514 in.) | - |
| Thickness | - | 31.89-31.97 mm (1.256-1.259 in.) | 31.77 mm (1.251 in.) | |
| End play | - | 0.06-0.19 mm (0.002-0.007 in.) | 0.3 mm (0.012 in.) | |
| Mainshaft 4th and 5th gears distance collar | I.D. | - | 35.002-35.012 mm (1.3780-1.3784 in.) | - |
| O.D. | - | 41.989-42.000 mm (1.6531-1.6535 in.) | - | |
| Length | - | 32.03-32.08 mm (1.261-1.263 in.) | - | |
| Mainshaft 6th gear | I.D. | - | 44.009-44.025 mm (1.7326-1.7333 in.) | - |
| Thickness | - | 28.89-28.97 mm (1.137-1.141 in.) | 28.77 mm (1.133 in.) | |
| End play | - | 0.06-0.19 mm (0.002-0.007 in.) | 0.3 mm (0.012 in.) | |
| Countershaft | Diameter of rear side cover needle bearing contact area | - | 30.020-30.029 mm (1.1819-1.1822 in.) | 29.97 mm (1.180 in.) |
| Diameter of transmission housing side needle bearing contact area | - | 34.002-34.018 mm (1.3387-1.3393 in.) | 33.95 mm (1.337 in.) | |
| Diameter of 2nd gear contact area | - | 43.984-44.000 mm (1.7317-1.7323 in.) | 43.93 mm (1.730 in.) | |
| Diameter of clutch housing side ball bearing contact area | - | 28.002-28.015 mm (1.1024-1.1030 in.) | 27.95 mm (1.100 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Countershaft 1st gear | I.D. | - | 57.010-57.029 mm (2.2445-2.2452 in.) | - |
| Thickness | 2000-2003 models | 31.18-31.26 mm (1.228-1.231 in.) | 31.06 mm (1.223 in.) | |
| 2004-2009 models | 27.88-27.96 mm (1.098-1.101 in.) | 27.76 mm (1.093 in.) | ||
| End play | 2000-2003 models | 0.04-0.22 mm (0.002-0.009 in.) | 0.3 mm (0.012 in.) | |
| 2004-2009 models | 0.04-0.17 mm (0.002-0.007 in.) | |||
| Countershaft 1st gear distance collar | O.D. | - | 50.987-51.000 mm (2.0074-2.0079 in.) | - |
| Length | - | 28.03-28.08 mm (1.104-1.106 in.) | - | |
| Countershaft 2nd gear | I.D. | - | 43.984-44.000 mm (1.7317-1.7323 in.) | - |
| Thickness | - | 32.88-32.96 mm (1.294-1.298 in.) | 32.76 mm (1.290 in.) | |
| End play | - | 0.04-0.17 mm (0.002-0.007 in.) | 0.3 mm (0.012 in.) | |
| Countershaft reverse gear | I.D. | - | 50.009-50.025 mm (1.9689-1.9695 in.) | - |
| Thickness | - | 26.38-26.46 mm (1.039-1.042 in.) | 26.26 mm (1.034 in.) | |
| End play | - | 0.04-0.22 mm (0.002-0.009 in.) | 0.3 mm (0.012 in.) | |
| Countershaft reverse gear distance collar | O.D. | - | 37.989-38.000 mm (1.4956-1.4961 in.) | - |
| Length | - | 25.53-25.58 mm (1.005-1.007 in.) | - | |
| Secondary shaft | Diameter of ball bearing contact area | - | 31.002-31.013 mm (1.2205-1.2210 in.) | 30.95 mm (1.219 in.) |
| Diameter of propeller shaft side tapered roller bearing contact area | - | 41.002-41.018 mm (1.6142-1.6149 in.) | 40.95 mm (1.612 in.) | |
| Diameter of transmission housing side tapered roller bearing contact area | - | 35.009-35.025 mm (1.3783-1.3790 in.) | 34.96 mm (1.376 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Starting torque (preload) | - | 1.86-2.84 N.m (19.0-29.0 kgf.cm, 16.5-25.2 lbf.in.) | Adjust | |
| Shift fork | Finger thickness | 1-2 shift fork | 7 4-7.6 mm (0.29-0.30 in.) | - |
| 3-4 shift fork | 6.2-6 4 mm (0.24-0.25 in.) | - | ||
| 5-6 shift fork | 6.2-6.4 mm (0 24-0.25 in.) | - | ||
| Reverse shift fork | 6.2-6.4 mm (0.24-0.25 in.) | - | ||
| Fork-to-synchro sleeve clearance | - | 0.35-0.65 mm (0.014-0.026 in.) | 1.00 mm (0.039 in.) | |
| Groove | To 1-2 shift lever | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) | |
| To shift arm A | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) | ||
| Shift arm A | I.D. | - | 16.000-16.027 mm (0.6299-0.6310 in.) | - |
| Finger width | - | 16.8-17.0 mm (0.661-0.669 in.) | 16.7 mm (0.657 in.) | |
| Shift arm A-to-shift forks | - | 0.2-0.6 mm (0.008-0.024 in.) | 0.7 mm (0.028 in.) | |
| 1-2 shift lever | Finger width | - | 17.0-17.2 mm (0.669-0.677 in.) | 16.9 mm (0.665 in.) |
| Lever-to-shift forks and pieces clearance | - | 0-0.4 mm (0-0.016 in.) | 0.5 mm (0.020 in.) | |
| 1-2 shift piece | Groove | To shift arm A | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) |
| 3-4 shift piece | Groove | To shift arm A | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) |
| Reverse shift piece | Groove | To 1-2 shift arm A | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) |
| To shift arm A | 17.2-17.4 mm (0.677-0.685 in.) | 17.1 mm (0.673 in.) | ||
| Synchro ring | Ring-to-gear clearance (ring pushed against gear) | 2000-2003 models 5th and 6th gears | 0.75-1.00 mm (0.030-0.039 in.) | 0.4 mm (0.016 in.) |
| 2004-2008 models 3rd, 4th, 5th, and 6th gears | 0.85-1.10 mm (0.033-0.043 in.) | 0.4 mm (0.016 in.) | ||
| Reverse gear | 0.85-1.10 mm (0.033-0.043 in.) | 0.4 mm (0.016 in.) | ||
| Double cone synchro | Outer syncro ring-to-synchro cone clearance (ring pushed against gear) | 2000-2003 models 1st and 2nd gears | 0.70-1.09 mm (0.028-0.043 in.) | 0.3 mm (0.012 in.) |
| 2004-2009 models 1st and 2nd gears | 0.58-1.09 mm (0.023-0.043 in.) | 0.3 mm (0.012 in.) | ||
| 2000-2003 models 3rd and 4th gears | 0.90-1.39 mm (0.035-0.055 in.) | 0.3 mm (0.012 in.) | ||
| Synchro cone-to-gear clearance (ring pushed against gear) | 2000-2003 models 1st, 3rd, and 4th gears | 0.50-1.04 mm (0.020-0.041 in.) | 0.3 mm (0.012 in.) | |
| 2004 model 1st gear | 0.33-1.04 mm (0.013-0.041 in.) | 0.3 mm (0.012 in.) | ||
| 2000-2003 models 2nd gear | 0.65-1.78 mm (0.026-0.070 in.) | 0.3 mm (0.012 in.) | ||
| 2004-2009 models 2nd gear | 0.33-1.04 mm (0.013-0.041 in.) | 0.3 mm (0.012 in.) | ||
| Outer synchro ring-to-gear clearance (ring pushed against gear) | 2000-2003 models 1st, 3rd, and 4th gears | 0.95-1.68 mm (0.037-0.066 in.) | 0.6 mm (0.024 in.) | |
| 2004-2009 models 1st gear | 0.95-1.35 mm (0.037-0.053 in.) | 0.6 mm (0.024 in.) | ||
| 2000-2003 models 2nd gear | 0.70-1.82 mm (0.028-0.072 in.) | 0.6 mm (0.024 in.) | ||
| 2004-2009 models 2nd gear | 0.95-1.35 mm (0.037-0.053 in.) | 0.6 mm (0.024 in.) | ||
| Oil pump | Inner rotor-to-outer rotor radial clearance | - | 1.14 mm (0.006 in.) max. | 0.20 mm (0.008 in.) |
| Rotor-to-transmission housing clearance | Radial clearance | 0.1-0.2 mm (0.004-0.008 in.) | 0.22 mm (0.009 in.) | |
| Axial clearance | 0.03-0.07 mm (0.001-0.003 in.) | Adjust | ||