Service Data
MANUAL TRANSMISSION COMPONENTS SERVICE SPECIFICATION
| Output shaft 2nd gear journal diameter: Minimum | 42.975 mm (1.6919 in.) |
| Output shaft 3rd gear journal diameter: Minimum | 31.969 mm (1.2586 in.) |
| Output shaft flange thickness: Minimum | 5.70 mm (0.2244 in.) |
| Output shaft runout: Maximum | 0.03 mm (0.0012 in.) |
| 1st gear inner race flange thickness: Minimum | 4.78 mm (0.1881 in.) |
| 1st gear inner race outer diameter: Minimum | 42.975 mm (1.6919 in.) |
| Counter gear bearing journal diameter: Minimum | 29.950 mm (1.1791 in.) |
| Counter 5th gear journal diameter: Minimum | 26.975 mm (1.0620 in.) |
| 1st, 2nd and 3rd gear thrust clearance: a: Standard b: Maximum |
a: 0.10 - 0.25 mm (0.0039 - 0.0098 in.) b: 0.25 mm (0.0098 in.) |
| Counter 5th gear thrust clearance: c: Standard d: Maximum |
c: 0.10 - 0.41 mm (0.0039 - 0.0161 in.) d: 0.41 mm (0.0161 in.) |
| 1st, 2nd and counter 5th gear radial clearance: e: Standard f: Maximum |
e: 0.009 - 0.060 mm (0.0004 - 0.0024 in.) f: 0.060 mm (0.0024 in.) |
| 3rd gear radial clearance: g: Standard h: Maximum |
g: 0.015 - 0.066 mm (0.0006 - 0.0026 in.) h: 0.066 mm (0.0026 in.) |
| Reverse idler gear radial clearance: i: Standard j: Maximum |
i: 0.041 - 0.074 mm (0.0016 - 0.0029 in.) j: 0.074 mm (0.0029 in.) |
| No. 1 and No. 2 shift fork to hub sleeve clearance: Maximum | 0.5 mm (0.020 in.) |
| No. 3 shift fork to hub sleeve clearance: Maximum | 0.84 mm (0.0331 in.) |
| Synchronizer ring to 1st, 3rd and 4th gear clearance: Minimum | 0.70 mm (0.0276 in.) |
| Synchronizer ring to 2nd and 3rd gear clearance: Minimum | 0.74 mm (0.0291 in.) |
| Input shaft snap ring thickness | Mark 1: 2.05 - 2.10 mm (0.0807 - 0.0827 in.) Mark 2: 2.10 - 2.15 mm (0.0827 - 0.0846 in.) Mark 3: 2.15 - 2.20 mm (0.0846 - 0.0866 in.) Mark 4: 2.20 - 2.25 mm (0.0866 - 0.0886 in.) Mark 5: 2.25 - 2.30 mm (0.0886 - 0.0906 in.) Mark 11: 2.30 - 2.35 mm (0.0906 - 0.0925 in.) Mark 12: 2.35 - 2.40 mm (0.0925 - 0.0945 in.) |
| Output shaft snap ring thickness No.2 clutch hub |
Mark C-1: 1.75 - 1.80 mm (0.0689 - 0.0709 in.) Mark D: 1.80 - 1.85 mm (0.0709 - 0.0728 in.) Mark 11: 1.86 - 1.91 mm (0.0732 - 0.0752 in.) Mark 12: 1.92 - 1.97 mm (0.0756 - 0.0776 in.) Mark 13: 1.98 - 2.03 mm (0.0780 - 0.0799 in.) Mark 14: 2.04 - 2.09 mm (0.0803 - 0.0823 in.) Mark 15: 2.10 - 2.15 mm (0.0827 - 0.0846 in.) |
| Output shaft snap ring thickness Rear bearing |
Mark 8: 2.31 - 2.36 mm (0.0909 - 0.0929 in.) Mark 9: 2.37 - 2.42 mm (0.0933 - 0.0953 in.) Mark 10: 2.43 - 2.48 mm (0.0957 - 0.0976 in.) Mark 11: 2.49 - 2.54 mm (0.0980 - 0.1000 in.) Mark 12: 2.55 - 2.60 mm (0.1004 - 0.1024 in.) Mark 13: 2.61 - 2.66 mm (0.1028 - 0.1047 in.) Mark 14: 2.68 - 2.73 mm (0.1055 - 0.1075 in.) Mark 15: 2.74 - 2.79 mm (0.1079 - 0.1098 in.) |
| Output shaft snap ring thickness Reverse gear |
Mark 5: 2.25 - 2.30 mm (0.0886 - 0.0906 in.) Mark 11: 2.30 - 2.35 mm (0.0906 - 0.0925 in.) Mark 12: 2.35 - 2.40 mm (0.0925 - 0.0945 in.) Mark 13: 2.40 - 2.45 mm (0.0945 - 0.0965 in.) Mark 14: 2.45 - 2.50 mm (0.0965 - 0.0984 in.) Mark 15: 2.50 - 2.55 mm (0.0984 - 0.1004 in.) Mark 16: 2.55 - 2.60 mm (0.1004 - 0.1024 in.) Mark 17: 2.61 - 2.66 mm (0.1028 - 0.1047 in.) Mark 18: 2.67 - 2.72 mm (0.1051 - 0.1071 in.) Mark 19: 2.73 - 2.78 mm (0.1075 - 0.1094 in.) Mark 20: 2.79 - 2.84 mm (0.1098 - 0.1118 in.) Mark 21: 2.85 - 2.90 mm (0.1122 - 0.1142 in.) Mark 22: 2.91 - 2.96 mm (0.1146 - 0.1165 in.) Mark 23: 2.97 - 3.02 mm (0.1169 - 0.1189 in.) |
| Coutner gear snap ring thickness Front bearing |
Mark A: 2.05 - 2.10 mm (0.0807 - 0.0827 in.) Mark B: 2.10 - 2.15 mm (0.0827 - 0.0846 in.) Mark C: 2.15 - 2.20 mm (0.0846 - 0.0866 in.) Mark D: 2.20 - 2.25 mm (0.0866 - 0.0886 in.) Mark E: 2.25 - 2.30 mm (0.0886 - 0.0906 in.) Mark F: 2.30 - 2.35 mm (0.0906 - 0.0925 in.) |
| Counter gear snap ring thickness No.3 clutch hub |
Mark 2: 2.06 - 2.11 mm (0.0811 - 0.0831 in.) Mark 3: 2.12 - 2.17 mm (0.0835 - 0.0854 in.) Mark 4: 2.18 - 2.23 mm (0.0858 - 0.0878 in.) Mark 5: 2.24 - 2.29 mm (0.0882 - 0.0902 in.) |
| Counter gear snap ring thickness Rear bearing |
Mark 1: 1.90 - 1.95 mm (0.0748 - 0.0768 in.) Mark 2: 1.96 - 2.01 mm (0.0772 - 0.0791 in.) Mark 3: 2.02 - 2.07 mm (0.0795 - 0.0815 in.) Mark 4: 2.08 - 2.13 mm (0.0819 - 0.0839 in.) Mark 5: 2.14 - 2.19 mm (0.0843 - 0.0862 in.) Mark 6: 2.20 - 2.25 mm (0.0866 - 0.0886 in.) Mark 7: 2.26 - 2.31 mm (0.0890 - 0.0909 in.) |
| Oil seal drive in depth | |
| Front bearing retainer (from retainer end) Extension housing Reverse restrict pin drive in depth |
12.2 +/- 0.5 mm (0.480 +/- 0.020 in.) 0 +/- 0.5 mm (0 +/- 0.020 in.) 16 - 17 mm (0.63 - 0.67 in.) |