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Service Data

MANUAL TRANSAXLE SERVICE SPECIFICATIONS

Input shaft  
  3rd & 4th gear journal diameter Min. 35.984 mm (1.4167 in.)
  5th gear journal diameter Min. 27.957 mm (1.1007 in.)
  Runout Max. 0.03 mm (0.0012 in.)
Output shaft  
  1st gear journal diameter Min. 37.610 mm (1.4807 in.)
  2nd gear journal diameter Min. 34.502 mm (1.3583 in.)
  Runout Max. 0.03 mm (0.0012 in.)
Gear thrust clearance  
  1st Max. 0.40 mm (0.0157 in.)
  2nd & 3rd Max. 0.35 mm (0.0138 in.)
  4th Max. 0.57 mm (0.0224 in.)
  5th Max. 0.65 mm (0.0256 in.)
Gear radial clearance  
  1st, 2nd & 3rd Max. 0.053 mm (0.0021 in.)
  4th Max. 0.051 mm (0.0020 in.)
  5th Max. 0.050 mm (0.0020 in.)
No. 1 and No. 3 shift fork to hub sleeve clearance Max. 0.35 mm (0.014 in.)
No. 2 shift fork to hub sleeve clearance Max. 0.69 mm (0.0272 in.)
Synchronizer ring to gear clearance  
  1st, 2nd & 5th Min. 0.7 mm (0.028 in.)
  3rd Min. 0.65 mm (0.0256 in.)
  4th Min. 0.75 mm (0.0295 in.)
Input shaft snap ring thickness Mark  
  No. 2 clutch hub H 2.30 mm (0.0906 in.)
  J 2.35 mm (0.0925 in.)
  K 2.40 mm (0.0945 in.)
  L 2.45 mm (0.0965 in.)
  M 2.50 mm (0.0984 in.)
  N 2.55 mm (0.1004 in.)
  P 2.60 mm (0.1024 in.)
  No. 3 clutch hub a 1.75 mm (0.0689 in.)
  b 1.80 mm (0.0709 in.)
  c 1.85 mm (0.0729 in.)
  d 1.90 mm (0.0748 in.)
  e 1.95 mm (0.0768 in.)
  f 2.00 mm (0.0787 in.)
  g 2.05 mm (0.0807 in.)
  h 2.10 mm (0.0827 in.)
  j 2.15 mm (0.0847 in.)
  Input shaft rear bearing 1 2.35 mm (0.0925 in.)
  2 2.40 mm (0.0945 in.)
  3 2.45 mm (0.0965 in.)
  4 2.50 mm (0.0984 in.)
  5 2.55 mm (0.1004 in.)
  6 2.60 mm (0.1024 in.)
  7 2.65 mm (0.1043 in.)
  8 2.70 mm (0.1063 in.)
Differential pinion to side gear backlash STD 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Output shaft rear bearing adjusting shim thickness Mark  
0 1.30 mm (0.0512 in.)
1 1.35 mm (0.0531 in.)
2 1.40 mm (0.0551 in.)
3 1.45 mm (0.0571 in.)
4 1.50 mm (0.0591 in.)
5 1.55 mm (0.0610 in.)
6 1.60 mm (0.0630 in.)
7 1.65 mm (0.0650 in.)
8 1.70 mm (0.0669 in.)
9 1.75 mm (0.0689 in.)
A 1.80 mm (0.0709 in.)
B 1.85 mm (0.0728 in.)
C 1.90 mm (0.0748 in.)
D 1.95 mm (0.0768 in.)
E 2.00 mm (0.0787 in.)
F 2.05 mm (0.0807 in.)
G 2.10 mm (0.0827 in.)
H 2.15 mm (0.0846 in.)
J 2.20 mm (0.0866 in.)
K 2.25 mm (0.0886 in.)
L 2.30 mm (0.0906 in.)
M 2.35 mm (0.0925 in.)
N 2.40 mm (0.0945 in.)
P 2.45 mm (0.0965 in.)
Q 2.50 mm (0.0984 in.)
Output shaft bearing preload (at starting)  
  New bearing 0.8 - 1.6 N.m (8 - 16 kgf.cm, 6.9 - 13.9 in..lbf)
  Reused bearing 0.5 - 1.0 N.m (5 - 10 kgf.cm, 4.3 - 8.7 in..lbf)
Oil pump clearance (4WD)  
  Rotor body STD 0.10 - 0.16 mm (0.0039 - 0.0063 in.)
  Rotor tip STD 0.08 - 0.15 mm (0.0031 - 0.0059 in.)
  Rotor side STD 0.03 - 0.08 mm (0.0012 - 0.0031 in.)
Differential side gear thrust washer thickness (2WD) 1.00 mm (0.0394 in.)
1.10 mm (0.0433 in.)
1.20 mm (0.0472 in.)
1.30 mm (0.0512 in.)
No.1 differential case (4WD)  
  Inner diameter STD 104.000 - 104.035 mm (4.0945 - 4.0959 in.)
  Max. 104.060 mm (4.0969 in.)
No.2 differential case (4WD)  
  Inner diameter STD 97.000 - 97.035 mm (3.8189 - 3.8203 in.)
  Max. 97.060 mm (3.8213 in.)
Front differential case (4WD)  
  Outer diameter (Part A) STD 103.929 - 103.964 mm (4.0917 - 4.0931 in.)
  Min. 103.850 mm (4.0887 in.)
  Outer diameter (Part B) STD 96.929 - 96.964 mm (3.8161 - 3.8175 in.)
  Min. 96.850 mm (3.8130 in.)
Conical spring washer height (4WD)  
  No.2 differential case side STD 2.60 - 2.80 mm (0.102 - 0.110 in.)
  Min. 2.50 mm (0.098 in.)
  No.1 differential case side STD 1.55 - 1.75 mm (0.061 - 0.069 in.)
  Min. 1.60 mm (0.063 in.)
Center differential side gear thrust washer thickness  
  Differential side gear subassembly side (4WD) MA 0.80 mm (0.0315 in.)
  MB 0.85 mm (0.0335 in.)
  MC 0.90 mm (0.0354 in.)
  MD 0.95 mm (0.0374 in.)
  ME 1.00 mm (0.0394 in.)
  MF 1.05 mm (0.0413 in.)
  MG 1.10 mm (0.0433 in.)
  MH 1.15 mm (0.0453 in.)
  MI 1.20 mm (0.0472 in.)
  MJ 1.25 mm (0.0492 in.)
  MK 1.30 mm (0.0512 in.)
  ML 1.35 mm (0.0531 in.)
  MN 1.40 mm (0.0551 in.)
Differential pinion to front side gear backlash (4WD) STD 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Front differential side gear thrust washer thickness Mark  
  Front differential case side (4WD) B 1.00 mm (0.0394 in.)
  C 1.05 mm (0.0413 in.)
  D 1.10 mm (0.0433 in.)
  E 1.15 mm (0.0453 in.)
  F 1.20 mm (0.0472 in.)
  G 1.25 mm (0.0492 in.)
Front differential side gear thrust washer thickness Mark  
  No.2 differential case side (4WD) A 0.95 mm (0.0374 in.)
  B 1.00 mm (0.0394 in.)
  C 1.05 mm (0.0413 in.)
  D 1.10 mm (0.0433 in.)
  E 1.15 mm (0.0453 in.)
  F 1.20 mm (0.0472 in.)
  G 1.25 mm (0.0492 in.)
  H 1.30 mm (0.0512 in.)
  J 1.35 mm (0.0531 in.)
  K 1.40 mm (0.0551 in.)
Center differential side gear thrust clearance (4WD) STD 0.16 - 0.25 mm (0.006 - 0.010 in.)
Center differential side gear thrust washer thickness  
  Front differential case side (4WD) 0 0.80 mm (0.0315 in.)
  1 0.85 mm (0.0335 in.)
  2 0.90 mm (0.0354 in.)
  3 0.95 mm (0.0374 in.)
  4 1.00 mm (0.0394 in.)
  5 1.05 mm (0.0413 in.)
  6 1.10 mm (0.0433 in.)
  7 1.15 mm (0.0453 in.)
  8 1.20 mm (0.0472 in.)
  9 1.25 mm (0.0492 in.)
  A 1.30 mm (0.0512 in.)
  B 1.35 mm (0.0531 in.)
  C 1.40 mm (0.0551 in.)
Differential side bearing adjusting shim thickness Mark  
0 2.00 mm (0.0787 in.)
1 2.05 mm (0.0807 in.)
2 2.10 mm (0.0827 in.)
3 2.15 mm (0.0846 in.)
4 2.20 mm (0.0866 in.)
5 2.25 mm (0.0886 in.)
6 2.30 mm (0.0906 in.)
7 2.35 mm (0.0925 in.)
8 2.40 mm (0.0945 in.)
9 2.45 mm (0.0965 in.)
A 2.50 mm (0.0984 in.)
B 2.55 mm (0.1004 in.)
C 2.60 mm (0.1024 in.)
D 2.65 mm (0.1043 in.)
E 2.70 mm (0.1063 in.)
F 2.75 mm (0.1083 in.)
G 2.80 mm (0.1102 in.)
H 2.85 mm (0.1122 in.)
Transmission case side oil seal drive in depth 2WD 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
4WD 0 ± 0.5 mm (0 ± 0.020 in.)
Transaxle case side drive in depth 2WD 0 ± 0.5 mm (0 ± 0.020 in.)
4WD 6.9 ± 0.5 mm (0.272 ± 0.020 in.)
Differential case side bearing preload (at starting)  
  New bearing (Output shaft preload plus) 0.8 - 1.6 N.m (8 - 16.3 kgf.cm, 7.1 - 14.2 in..lbf)
  Reused bearing (Output shaft preload plus) 0.5 - 1.0 N.m (5.1 - 10.2 kgf.cm, 4.4 - 8.6 in..lbf)
Transfer
Drive pinion preload (at starting) (For use with SST) 0.9 - 1.3 N.m (9 - 13 kgf.cm, 7.8 - 11.3 in..lbf)
Drive pinion total preload (at starting) (For use with SST) 1.0 - 1.6 N.m (10 - 16 kgf.cm, 8.9 - 13.8 in..lbf)
Ring gear backlash 0.10 - 0.15 mm (0.0039 - 0.0059 in.)
Ring gear runout 0.1 mm (0.004 in.)
Center differential control coupling runout 0.07 mm (0.0028 in.)
Drive pinion preload (at starting) (For use with SST)  
New bearing 0.9 - 1.4 N.m (9 - 14 kgf.cm, 7.8 - 12.4 in..lbf)
Reused bearing 0.8 - 1.1 N.m (8 - 11 kgf.cm, 7.0 - 9.7 in..lbf)
Backlash adjust washer thickness Mark  
AA 2.07 mm (0.0815 in.)
AB 2.10 mm (0.0827 in.)
AC 2.13 mm (0.0839 in.)
BA 2.16 mm (0.0850 in.)
BB 2.19 mm (0.0862 in.)
BC 2.22 mm (0.0874 in.)
CA 2.25 mm (0.0886 in.)
CB 2.28 mm (0.0898 in.)
CC 2.31 mm (0.0909 in.)
DA 2.34 mm (0.0921 in.)
DB 2.37 mm (0.0933 in.)
DC 2.40 mm (0.0945 in.)
EA 2.43 mm (0.0957 in.)
EB 2.46 mm (0.0969 in.)
EC 2.49 mm (0.0980 in.)
FA 2.52 mm (0.0992 in.)
FB 2.55 mm (0.1004 in.)
FC 2.58 mm (0.1016 in.)
GA 2.61 mm (0.1028 in.)
GB 2.64 mm (0.1039 in.)
GC 2.67 mm (0.1051 in.)
HA 2.70 mm (0.1063 in.)
HB 2.73 mm (0.1075 in.)
HC 2.76 mm (0.1087 in.)
JA 2.79 mm (0.1098 in.)
JB 2.82 mm (0.1110 in.)
JC 2.85 mm (0.1122 in.)
KA 2.88 mm (0.1134 in.)
KB 2.91 mm (0.1146 in.)
KC 2.94 mm (0.1157 in.)
LA 2.97 mm (0.1169 in.)
LB 3.00 mm (0.1181 in.)
Tooth contact adjust washer thickness Mark  
AA 1.20 mm (0.0472 in.)
AB 1.21 mm (0.0476 in.)
AC 1.22 mm (0.0480 in.)
BA 1.23 mm (0.0484 in.)
BB 1.24 mm (0.0488 in.)
BC 1.25 mm (0.0492 in.)
CA 1.26 mm (0.0496 in.)
CB 1.27 mm (0.0500 in.)
CC 1.28 mm (0.0504 in.)
DA 1.29 mm (0.0508 in.)
DB 1.30 mm (0.0512 in.)
DC 1.31 mm (0.0516 in.)
EA 1.32 mm (0.0520 in.)
EB 1.33 mm (0.0524 in.)
EC 1.34 mm (0.0528 in.)
FA 1.35 mm (0.0531 in.)
FB 1.36 mm (0.0535 in.)
FC 1.37 mm (0.0539 in.)
GA 1.38 mm (0.0543 in.)
GB 1.39 mm (0.0547 in.)
GC 1.40 mm (0.0551 in.)
HA 1.41 mm (0.0555 in.)
HB 1.42 mm (0.0559 in.)
HC 1.43 mm (0.0563 in.)
JA 1.44 mm (0.0567 in.)
JB 1.45 mm (0.0571 in.)
JC 1.46 mm (0.0575 in.)
KA 1.47 mm (0.0579 in.)
KB 1.48 mm (0.0583 in.)
KC 1.49 mm (0.0587 in.)
LA 1.50 mm (0.0591 in.)
LB 1.51 mm (0.0594 in.)
LC 1.52 mm (0.0598 in.)
MA 1.53 mm (0.0602 in.)
MB 1.54 mm (0.0606 in.)
MC 1.55 mm (0.0610 in.)
NA 1.56 mm (0.0614 in.)
NB 1.57 mm (0.0618 in.)
NC 1.58 mm (0.0622 in.)
PA 1.59 mm (0.0626 in.)
PB 1.60 mm (0.0630 in.)
PC 1.61 mm (0.0634 in.)
QA 1.62 mm (0.0638 in.)
QB 1.63 mm (0.0642 in.)
QC 1.64 mm (0.0646 in.)
RA 1.65 mm (0.0650 in.)
Drive pinion total preload (at starting) (For use with SST)  
(Drive pinion preload plus)  
New bearing 0.2 - 0.4 N.m (2 - 4 kgf.cm, 1.7 - 3.5 in..lbf)
Reused bearing 0.1 - 0.3 N.m (1 - 3 kgf.cm, 0.9 - 2.6 in..lbf)
Preload adjust washer thickness Mark  
AA 1.47 mm (0.0579 in.)
AB 1.50 mm (0.0591 in.)
AC 1.53 mm (0.0602 in.)
BA 1.56 mm (0.0614 in.)
BB 1.59 mm (0.0626 in.)
BC 1.62 mm (0.0638 in.)
CA 1.65 mm (0.0650 in.)
CB 1.68 mm (0.0661 in.)
CC 1.71 mm (0.0673 in.)
DA 1.74 mm (0.0685 in.)
DB 1.77 mm (0.0697 in.)
DC 1.80 mm (0.0709 in.)
EA 1.83 mm (0.0720 in.)
EB 1.86 mm (0.0732 in.)
EC 1.89 mm (0.0744 in.)
FA 1.92 mm (0.0756 in.)
FB 1.95 mm (0.0768 in.)
FC 1.98 mm (0.0780 in.)
GA 2.01 mm (0.0791 in.)
GB 2.04 mm (0.0803 in.)
GC 2.07 mm (0.0815 in.)
HA 2.10 mm (0.0827 in.)
HB 2.13 mm (0.0839 in.)
HC 2.16 mm (0.0850 in.)
JA 2.19 mm (0.0862 in.)
JB 2.22 mm (0.0874 in.)
JC 2.25 mm (0.0886 in.)
KA 2.28 mm (0.0898 in.)
KB 2.31 mm (0.0909 in.)
KC 2.34 mm (0.0921 in.)
LA 2.37 mm (0.0933 in.)
LB 2.40 mm (0.0945 in.)
LC 2.43 mm (0.0957 in.)
MA 2.46 mm (0.0969 in.)
MB 2.49 mm (0.0980 in.)
MC 2.52 mm (0.0992 in.)
NA 2.55 mm (0.1004 in.)
NB 2.58 mm (0.1016 in.)
Bearing retainer RH oil seal drive in depth Inner side 1.5 - 2.5 mm (0.059 - 0.098 in.)
Outer side 0.7 - 1.3 mm (0.028 - 0.071 in.)
Transfer case oil seal drive in depth 8.7 - 9.3 mm (0.343 - 0.366 in.)
Extension housing oil seal drive in depth 1.1 - 1.9 mm (0.043 - 0.075 in.)
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