Manual Transmission and M/T Differential
MANUAL TRANSMISSION AND M/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Manual transmission fluid | Capacity Use genuine Honda MTF | Fluid change | 1.5L (1.6 US qt) | - |
| Overhaul | 1.6 L (1.7 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 distance 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 (1.0227-1.0232 in.) | 25.92 mm (1.020 in.) | |
| Diameter of pilot bearing contact area | - | 14.870-14.890 mm (0.5854-0.5862 in.) | - | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Mainshaft 3rd and 4th gear | I.D. | - | 39.009-39.025 mm (1.5358-1.5364 in.) | 39.07 mm (1.538 in.) |
| Clearance | 2nd-3rd | 0.06-0.21 mm (0.002-0.008 in.) | 0.33 mm (0.013 in.) | |
| Endplay | 4th | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.012 in.) | |
| Thickness | 3rd | 27.92-27.97 mm (1.099-1.101 in.) | 27.85 mm (1.096 in.) | |
| 4th | 27.02-27.07 mm (1.064-1.066 in.) | 26.65 mm (1.049 in.) | ||
| Mainshaft 5th gear | I.D. | - | 39.009-39.025 mm (1.5358-1.5364 in.) | 39.07 mm (1.538 in.) |
| End play (Distance collar side) |
- | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.012 in.) | |
| Thickness | - | 28.92-28.97 mm (1.139-1.141 in.) | 28.85 mm (1.136 in.) | |
| Mainshaft 4th, 5th gear distance 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.) | |
| Overall Length | - | 51.97-52.03 mm (2.046-2.048 in.) | - | |
| Length of needle bearing contact area | 4th, 5th | 24.03-24.06 mm (0.946-0.947 in.) | - | |
| MBS distance collar | I.D. | - | 26.02-26.17 mm (1.024-1.030 in.) | - |
| Length | - | 12.00-12.05 mm (0.472-0.474 in.) | - | |
| Countershaft | Diameter of needle bearing contact area (transmission housing side) | - | 34.000-34.015 mm (1.3386-1.3392 in.) | 33.95 mm (1.337 in.) |
| Diameter of ball bearing contact area (clutch housing side) | - | 24.980-24.993 mm (0.9835-0.9840 in.) | 24.93 mm (0.981 in.) | |
| Diameter of 1st gear distance collar contact area | - | 36.487-36.500 mm (1.4365-1.4370 in.) | 36.44 mm (1.435 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Countershaft 1st gear | I.D. | - | 48.509-48.525 mm (1.9098-1.9104 in.) | 48.580 mm (1.9126 in.) |
| End play (distance collar side) |
- | 0.03-0.12 mm (0.001-0.005 in.) | 0.24 mm (0.009 in.) | |
| Thickness | - | 27.42-27.47 mm (1.080-1.081 in.) | 27.39 mm (1.078 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 1st gear distance collar | I.D. | - | 36.50-36.51 mm (1.4370-1.4373 in.) | 36.52 mm (1.438 in.) |
| O.D. | - | 44.489-45.000 mm (1.7515-1.7717 in.) | 44.44 mm (1.7500 in.) | |
| Overall Length | - | 30.50-30.54 mm (1.201-1.202 in.) | - | |
| Length of needle bearing contact area | - | 26.53-26.58 mm (1.044-1.046 in.) | - | |
| Countershaft 2nd gear distance 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.) | |
| Length | - | 27.53-27.56 mm (1.084-1.085 in.) | 27.51 mm (1.083 in.) | |
| Reverse idler gear | I.D. | - | 15.016-15.043 mm (0.5912-0.5922 in.) | 15.08 mm (0.594 in.) |
| Gear-to-reverse idler gear shaft clearance | - | 0.032-0.077 mm (0.0013-0.0030 in.) | 0.14 mm (0.006 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.) | ||
| Synchro ring | Ring-to-gear clearance (Ring pushed against gear) | - | 0.85-1.10 mm (0.033-0.043 in.) | 0.4 mm (0.02 in.) |
| Shift fork | Finger thickness | 1st/2nd, 3rd/4th | 7.4-7.6 mm (0.29-0.30 in.) | - |
| 5th | 6.7-6.9 mm (0.26-0.27 in.) | - | ||
| Fork-to-synchro sleeve clearance | - | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.04 in.) | |
| Reverse shift fork | Finger width | - | 13.5-13.8 mm (0.53-0.54 in.) | - |
| Fork-to-reverse idler gear clearance | - | 1.30-1.90 mm (0.051-0.075 in.) | 2.5 mm (0.10 in.) | |
| Shift arm | I.D. | - | 13.973-14.000 mm (0.5501-0.5512 in.) | - |
| Finger width | - | 12.9-13.0 mm (0.508-0.512 in.) | - | |
| Shift arm-to-shift fork clearance | - | 0.2-0.5 mm (0.01-0.02 in.) | 0.62 mm (0.024 in.) | |
| Select lever | Finger width | - | 12.80-12.95 mm (0.504-0.510 in.) | - |
| Change lever | Shaft-to-select lever clearance | - | 0.05-0.35 mm (0.002-0.014 in.) | 0.55 mm (0.022 in.) |
| Groove width | - | 13.00-13.15 mm (0.512-0.518 in.) | - | |
| Shaft-to-shift arm clearance | - | 0.013-0.070 mm (0.0005-0.0028 in.) | 0.1 mm (0.004 in.) | |
| M/T differential pinion gear | Backlash | - | 0.05-0.15 mm (0.002-0.006 in.) | - |
| M/T differential 80 mm shim | 80 mm shim-to-bearing outer race clearance in transmission housing | - | 0.01-0.1 mm (0.0004-0.004 in.) | Adjust |