Service Data

5th gear thrust clearance	Standard Maximum	0.10 to 0.55 mm (0.00394 to 0.0217 in.) 0.55 mm (0.0217 in.)
5th gear radial clearance	NSK made Standard Maximum KOYO made Standard Maximum	0.015 to 0.056 mm (0.000591 to 0.00220 in.) 0.056 mm (0.00220 in.) 0.015 to 0.058 mm (0.000591 to 0.00228 in.) 0.058 mm (0.00228 in.)
No. 3 synchronizer ring back and 5th gear spline end clearance	Standard	0.75 to 1.65 mm (0.0295 to 0.0649 in.)
	Minimum	0.75 mm (0.0295 in.)
No. 3 transmission hub sleeve and No. 3 gear shift fork clearance	Standard	0.3 to 0.5 mm (0.0118 to 0.0197 in.)
5th gear inner diameter	Standard Maximum	29.915 to 29.931 mm (1.1778 to 1.1783 in.) 29.931 mm (1.1783 in.)
Reverse idler gear inner diameter	Standard Maximum	18.040 to 18.058 mm (0.7102 to 0.7109 in.) 18.058 mm (0.7109 in.)
Reverse idler gear outer diameter	Standard Minimum	17.966 to 17.984 mm (0.7073 to 0.7080 in.) 17.966 mm (0.7073 in.)
Front transaxle case oil seal drive in depth	-	15.6 mm to 16.0 mm (0.6141 to 0.6299 in.)
Input shaft front bearing drive in depth	-	0 to 0.3 mm (0 to 0.0118 in.)
Shift and select lever shaft slide ball bearing drive in depth	-	0 to 0.5 mm (0 to 0.0197 in.)
Shift and select lever shaft oil seal drive in depth	-	9.7 to 10.3 mm (0.382 to 0.406 in.)
Front differential case tapered roller bearing preload	New bearing Used bearing	0.78 to 1.57 Nm (7.95 to 16.0 kgfcm, 6.9 to 13.89 in.lbf) 0.49 to 0.98 Nm (5.0 to 10.0 kgfcm, 4.34 to 8.67 in.lbf)
Front differential case shim thickness	AA BB CC DD EE FF GG HH JJ KK LL MM NN PP QQ RR SS TT UU	2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) 2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 in.)
Transmission case oil seal drive in depth	-	9.6 to 10.2 mm (0.378 to 0.402 in.)
Transaxle case oil seal drive in depth	-	1.4 to 2.0 mm (0.0551 to 0.0787 in.)
Reverse restrict pin slotted pin drive in depth	-	15.5 to 16.5 mm (0.6102 to 0.6496 in.)
No. 3 transmission clutch hub snap ring clearance	-	0.1 mm (0.00394 in.) or less
No. 3 transmission clutch hub snap ring thickness	A B C D E F G	2.25 mm (0.0886 in.) 2.31 mm (0.0909 in.) 2.37 mm (0.0933 in.) 2.43 mm (0.0957 in.) 2.49 mm (0.0980 in.) 2.55 mm (0.1004 in.) 2.61 mm (0.1028 in.)
Control shaft cover oil seal drive in depth	-	0.2 to 1.2 mm (0.00787 to 0.0472 in.)
4th gear thrust clearance	Standard Maximum	0.10 to 0.55 mm (0.00394 to 0.0217 in.) 0.55 mm (0.0217 in.)
3rd gear thrust clearance	Standard Maximum	0.10 to 0.35 mm (0.00394 to 0.0138 in.) 0.35 mm (0.0138 in.)
4th gear radial clearance	Standard Maximum	0.009 to 0.050 mm (0.000354 to 0.00197 in.) 0.050 mm (0.00197 in.)
3rd gear radial clearance	NSK made Standard Maximum KOYO made Standard Maximum	0.015 to 0.056 mm (0.000591 to 0.00220 in.) 0.056 mm (0.00220 in.) 0.015 to 0.058 mm (0.000591 to 0.00228 in.) 0.058 mm (0.00228 in.)
Input shaft runout	Maximum	0.015 mm (0.000591 in.)
Input shaft outer diameter	Standard Part A Part B Part C Part D Minimum Part A Part B Part C Part D	24.885 to 24.900 mm (0.9797 to 0.9803 in.) 28.991 to 29.006 mm (1.1414 to 1.1420 in.) 30.985 to 31.000 mm (1.2198 to 1.2204 in.) 24.985 to 25.000 mm (0.9836 to 0.9842 in.) 24.885 mm (0.9797 in.) 28.991 mm (1.1414 in.) 30.985 mm (1.2198 in.) 24.985 mm (0.9836 in.)
4th gear inside diameter	Standard Maximum	34.015 to 34.031 mm (1.3391 to 1.3398 in.) 34.031 mm (1.3398 in.)
3rd gear inside diameter	Standard Maximum	36.015 to 36.031 mm (1.4179 to 1.4185 in.) 36.031 mm (1.4185 in.)
3rd gear synchronizer ring back and 3rd gear spline end clearance	Standard Minimum	0.75 to 1.65 mm (0.0295 to 0.0649 in.) 0.75 mm (0.0295 in.)
4th gear synchronizer ring back and 4th gear spline end clearance	Standard Minimum	0.65 to 1.75 mm (0.0256 to 0.0689 in.) 0.65 mm (0.0256 in.)
No. 2 gear shift fork claw and glove of the No. 2 transmission hub sleeve clearance	-	0.15 to 0.35 mm (0.00591 to 0.0137 in.)
No. 2 transmission clutch hub snap ring clearance	-	0.1 mm (0.00394 in.) or less
No. 2 transmission clutch hub snap ring thickness	0 1 2 3 4 5	2.30 mm (0.0906 in.) 2.36 mm (0.0929 in.) 2.42 mm (0.0953 in.) 2.48 mm (0.0976 in.) 2.54 mm (0.1000 in.) 2.60 mm (0.1024 in.)
Input shaft rear bearing shaft snap ring clearance	-	0.1 mm (0.00394 in.) or less
Input shaft rear bearing shaft snap ring thickness	A B C D E F	2.29 mm (0.0901 in.) 2.35 mm (0.0925 in.) 2.41 mm (0.0948 in.) 2.47 mm (0.0972 in.) 2.53 mm (0.0996 in.) 2.59 mm (0.1019 in.)
1st gear thrust clearance	Standard Maximum	0.10 to 0.40 mm (0.00394 to 0.0157 in.) 0.40 mm (0.0157 in.)
2nd gear thrust clearance	Standard Maximum	0.10 to 0.55 mm (0.00394 to 0.0217 in.) 0.55 mm (0.0217 in.)
1st gear radial clearance	NSK made Standard Maximum KOYO made Standard Maximum	0.015 to 0.056 mm (0.000591 to 0.00220 in.) 0.056 mm (0.00220 in.) 0.015 to 0.058 mm (0.000591 to 0.00228 in.) 0.058 mm (0.00228 in.)
2nd gear radial clearance	NSK made Standard Maximum KOYO made Standard Maximum	0.015 to 0.056 mm (0.000591 to 0.00220 in.) 0.056 mm (0.00220 in.) 0.015 to 0.058 mm (0.000591 to 0.00228 in.) 0.058 mm (0.00228 in.)
Output shaft runout	Maximum	0.015 mm (0.000591 in.)
Output shaft outer diameter	Part A Part B Part C	31.985 to 32.000 mm (1.2592 to 1.2598 in.) 37.985 to 38.000 mm (1.4955 to 1.4961 in.) 32.985 to 33.000 mm (1.2986 to 1.2992 in.)
2nd gear inside diameter	Standard Maximum	38.015 to 38.031 mm (1.4967 to 1.4972 in.) 38.031 mm (1.4972 in.)
1st gear inside diameter	Standard Maximum	44.015 to 44.031 mm (1.7328 to 1.7335 in.) 44.031 mm (1.7335 in.)
1st gear thrust washer thickness	Standard Minimum	5.975 to 6.025 mm (0.2352 to 0.2372 in.) 5.975 mm (0.2352 in.)
No. 2 synchronizer ring set back and 2nd gear spline end clearance	Standard Minimum	0.60 to 1.40 mm (0.0236 to 0.0551 in.) 0.60 mm (0.0236 in.)
No. 1 synchronizer ring set back and 1st gear spline end clearance	Standard Minimum	0.60 to 1.40 mm (0.0236 to 0.0551 in.) 0.60 mm (0.0236 in.)
Reverse gear glove and reverse gear shift fork claw clearance	-	0.15 to 0.35 mm (0.00591 to 0.0138 in.)
No. 1 clutch hub shaft snap ring clearance	-	0.1 mm (0.0394 in.) or less
No. 1 clutch hub shaft snap ring thickness	A B C D E F	2.50 mm (0.0984 in.) 2.56 mm (0.1008 in.) 2.62 mm (0.1031 in.) 2.68 mm (0.1055 in.) 2.74 mm (0.1079 in.) 2.80 mm (0.1102 in.)
Shift lever slotted pin (for select inner lever) drive in depth	-	3.0 to 4.0 mm (0.1181 to 01575 in.)
Shift lever slotted pin (for No. 1 shift lever inner) drive in depth	-	-0.5 to 0.5 mm (-0.197 to 0.0197 in.)
Shift lever slotted pin (for No. 2 shift lever inner) drive in depth	-	1.0 to 2.0 mm (0.0394 to 0.0787 in.)
Front differential pinion thrust washer	Minimum	0.92 mm (0.0362 in.)
Front No. 1 differential pinion shaft outer diameter	Minimum	16.982 mm (0.6685 in.)
Front differential side gear backlash	Standard backlash	0.05 to 0.20 mm (0.00197 to 0.00787 in.)
Front differential side gear thrust washer thickness	41361-22140	0.95 mm (0.0374 in.)
	41361-22020	1.00 mm (0.0394 in.)
	41361-22150	1.05 mm (0.0413 in.)
	41361-22030	1.10 mm (0.0433in.)
	41361-22160	1.15 mm (0.0452in.)
	41361-22040	1.20 mm (0.0472 in.)
Back-up light switch	Push Release	Below 1 Ω 10 kΩ or higher