Service Data
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (1 OF 6)
| Manual transaxle assy | ||
| 5th gear thrust clearance | STD: | 0.10 to 0.57 mm (0.0039 to 0.02244 in.) |
| Max: | 0.57 mm (0.02244 in.) | |
| 5th gear radial clearance | KOYO made STD: | 0.015 to 0.058 mm (0.0006 to 0.0023 in.) |
| Max: | 0.058 mm (0.0023 in.) | |
| NSK made STD: | 0.015 to 0.056 mm (0.0006 to 0.0022 in.) | |
| Max: | 0.056 mm (0.0022 in.) | |
| Synchronizer ring No.3 back and 5th gear spline end clearance | STD: | 0.75 to 1.65 mm (0.0295 to 0.0650 in.) |
| Min: | 0.75 mm (0.0295 in.) | |
| Transmission hub sleeve No.3 and gear shift fork No.3 clearance | STD: | 0.3 to 0.5 mm (0.012 to 0.020 in.) |
| 5th gear inner diameter | STD: | 29.915 to 29.931mm (1.1778 to 1.1784 in.) |
| Max: | 29.931mm (1.1784 in.) | |
| Reverse idler gear sub-assy inner diameter | STD: | 18.040 to 18.058 mm (0.7102 to 0.7109 in.) |
| Max: | 18.058 mm (0.7109 in.) | |
| Reverse idler gear shaft outer diameter | STD: | 17.966 to 17.984 mm (0.7073 to 0.7080 in.) |
| Min: | 17.966 mm (0.7073 in.) | |
| Front transaxle case oil seal drive in depth | 15.6 to 16.0 mm (0.6142 to 0.6299 in.) | |
| Input shaft front bearing drive in depth | 0 to 0.3 mm (0 to 0.012 in.) | |
| Shift & Select lever shaft bimetal formed bush drive in depth | 0 to 0.5 mm (0 to 0.020 in.) | |
| Front differential case tapered roller bearing preload | New bearing | 0.78 to 1.57 N.m (8 to 16 kgf.cm, 6.9 to 13.9 in..lbf) |
| Front differential case shim thickness | AA: | 2.10 mm (0.0827 in.) |
| BB: | 2.15 mm (0.0846 in.) | |
| CC: | 2.20 mm (0.0866 in.) | |
| DD: | 2.25 mm (0.0886 in.) | |
| EE: | 2.30 mm (0.0906 in.) | |
| FF: | 2.35 mm (0.0925 in.) | |
| GG: | 2.40 mm (0.0945 in.) | |
| HH: | 2.45 mm (0.0965 in.) | |
| JJ: | 2.50 mm (0.0984 in.) | |
| KK: | 2.55 mm (0.1004 in.) | |
| LL: | 2.60 mm (0.1024 in.) | |
| MM: | 2.65 mm (0.1043 in.) | |
| NN: | 2.70 mm (0.1063 in.) | |
| PP: | 2.75 mm (0.1083 in.) | |
| QQ: | 2.80 mm (0.1102 in.) | |
| RR: | 2.85 mm (0.1122 in.) | |
| SS: | 2.90 mm (0.1142 in.) | |
| TT: | 2.95 mm (0.1161 in.) | |
| UU: | 3.00 mm (0.1181 in.) | |
| Transmission case oil seal drive in depth | 2.1 ± 2.7 mm (0.0827 ± 0.1063 in.) | |
| Transaxle case oil seal drive in depth | 1.6 ± 2.2 mm (0.0630 ± 0.0866 in.) | |
| Reverse restrict pin slotted pin drive in depth | 16.0 ± 17.0 mm (0.630 ± 0.670 in.) | |
| Transmission clutch hub No.3 snap ring thickness | A: | 2.25 mm (0.0886 in.) |
| B: | 2.31 mm (0.0909 in.) | |
| C: | 2.37 mm (0.0933 in.) | |
| D: | 2.43 mm (0.0957 in.) | |
| E: | 2.49 mm (0.0980 in.) | |
| F: | 2.55 mm (0.1004 in.) | |
| G: | 2.61 mm (0.1028 in.) | |
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (2 OF 6)
| Input shaft assy | ||
| 4th gear thrust clearance | STD: | 0.1 to 0.55 mm (0.0039 to 0.0217 in.) |
| Max: | 0.55 mm (0.0217 in.) | |
| 3rd gear thrust clearance | STD: | 0.1 to 0.35 mm (0.0039 to 0.0138 in.) |
| Max: | 0.35 mm (0.0138 in.) | |
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (3 OF 6)
| 4th gear radial clearance | STD: | 0.009 to 0.050 mm (0.0004 to 0.0020 in.) |
| Max: | 0.050 mm (0.0023 in.) | |
| 3rd gear radial clearance | KOYO made STD: | 0.015 to 0.058 mm (0.0006 to 0.0023 in.) |
| Max: | 0.058 mm (0.0023 in.) | |
| NSK made STD: | 0.015 to 0.056 mm (0.0006 to 0.0022 in.) | |
| Max: | 0.056 mm (0.0022 in.) | |
| Input shaft runout | Max: | 0.015 mm (0.0006 in.) |
| Input shaft outer diameter | STD: Part A | 24.885 to 24.900 mm (0.9797 to 0.9803 in.) |
| Part B | 28.991 to 29.006 mm (1.1413 to 1.1419 in.) | |
| Part C | 30.985 to 31.000 mm (1.2198 to 1.2204 in.) | |
| Part D | 24.985 to 25.000 mm (0.9836 to 0.9842 in.) | |
| Min: Part A | 24.885 mm (0.9797 in.) | |
| Part B | 28.991 mm (1.1413 in.) | |
| Part C | 30.985 mm (1.2198 in.) | |
| Part D | 24.985 mm (0.9836 in.) | |
| 4th gear inside diameter | STD: | 34.015 to 34.031 mm (1.3391 to 1.3398 in.) |
| Max: | 34.031 mm (1.3398 in.) | |
| 3rd gear inside diameter | STD: | 36.015 to 36.031 mm (1.4179 to 1.4185 in.) |
| Max: | 36.031 mm (1.4185 in.) | |
| 3rd gear synchronizer ring back and 3rd gear spline end clearance | Min: | 0.75 mm (0.0295 in.) |
| 4th gear synchronizer ring back and 3rd gear spline end clearance | Min: | 0.75 mm (0.0295 in.) |
| Gear shift fork No.2 claw and glove of the transmission hub sleeve No.2 clearance | 0.15 to 0.35 mm (0.0059 to 0.0137 in.) | |
| Transmission hub sleeve No.2 clearance | 0.15 to 0.35 mm (0.0059 to 0.0137 in.) | |
| Transmission clutch hub No.2 snap ring thickness | 0: | 2.30 mm (0.0906 in.) |
| 1: | 2.36 mm (0.0929 in.) | |
| 2: | 2.42 mm (0.0953 in.) | |
| 3: | 2.48 mm (0.0976 in.) | |
| 4: | 2.54 mm (0.1000 in.) | |
| 5: | 2.60 mm (0.1024 in.) | |
| Input shaft rear bearing shaft snap ring clearance | 0.1 mm (0.0039 in.) or less | |
| Input shaft rear bearing shaft snap ring thickness | A: | 2.29 mm (0.0901 in.) |
| B: | 2.35 mm (0.0925 in.) | |
| C: | 2.41 mm (0.0948 in.) | |
| D: | 2.47 mm (0.0972 in.) | |
| E: | 2.53 mm (0.0996 in.) | |
| F: | 2.59 mm (0.1019 in.) | |
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (4 OF 6)
| Output shaft assy | ||
| 1st gear thrust clearance | STD: | 0.10 to 0.40 mm (0.0039 to 0.0157 in.) |
| 2nd gear thrust clearance | STD: | 0.10 to 0.45 mm (0.0039 to 0.0177 in.) |
| 1st gear radial clearance | KOYO made: | 0.015 to 0.058 mm (0.0006 to 0.0023 in.) |
| NSK made: | 0.015 to 0.056 mm (0.0006 to 0.0022 in.) | |
| 2nd gear radial clearance | KOYO made: | 0.015 to 0.058 mm (0.0006 to 0.0023 in.) |
| NSK made: | 0.015 to 0.056 mm (0.0006 to 0.0022 in.) | |
| Output shaft maximum run out | 0.015 mm (0.0006 in.) | |
| Output shaft outer diameter | Part: A | 31.985 mm (1.2592 in.) |
| B | 37.985 mm (1.4955 in.) | |
| C | 32.985 mm (1.2986 in.) | |
| 2nd gear inside diameter | New: | 38.015 to 38.031 mm (1.4967 to 1.4972 in.) |
| Max: | 38.031 mm (1.4972 in.) | |
| 1st gear inside diameter | New: | 44.015 to 44.031 mm (1.7329 to 1.7335 in.) |
| Max: | 44.031 mm (1.7335 in.) | |
| 1st gear thrust washer thickness | New: | 5.975 to 6.025 mm (0.2352 to 0.2372 in.) |
| Min: | 5.975 mm (0.2352 in.) | |
| Synchronizer ring set No.2 back and 2nd gear spline end clearance | 0.75 to 1.65 mm (0.0295 to 0.065 in.) | |
| Synchronizer ring set No.1 back and 2nd gear spline end clearance | 0.75 to 1.65 mm (0.0295 to 0.065 in.) | |
| Reverse gear glove and reverse gear shift fork claw clearance | 0.15 to 0.35 mm (0.0059 to 0.014 in.) | |
| Clutch hub No,1 shaft snap ring clearance | 0.1 mm (0.039 in.) or less | |
| Clutch hub No.1 shaft snap ring thickness | A: | 2.50 mm (0.0984 in.) |
| B: | 2.56 mm (0.1008 in.) | |
| C: | 2.62 mm (0.1031 in.) | |
| D: | 2.68 mm (0.1055 in.) | |
| E: | 2.74 mm (0.1079 in.) | |
| F: | 2.80 mm (0.1102 in.) | |
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (5 OF 6)
| Shift & Select lever shaft assy | |
| Control shaft cover oil seal drive in depth | 0.2 to 1.2 mm (0.079 to 0.0472 in.) |
| Shift lever slotted pin (for select inner lever) drive in depth | 3.0 to 4.0 mm (0.1181 to 0.1575 in.) |
| Shift lever slotted pin (for shift lever inner No.1) drive in depth | -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
| Shift lever slotted pin (for shift lever inner No.2) drive in depth | -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
MANUAL TRANSMISSION/TRANSAXLE SERVICE DATA (6 OF 6)
| Differential case assy | ||
| Front differential side gear backlash | 0.05 to 0.20 mm (0.0020 to 0.0079 in.) | |
| Front differential pinion thrust washer | Min | 0.94 mm (0.03701 in.) |
| Front differential pinion shaft No.1 outer diameter | Min | 16.982 mm (0.6685 in.) |