Standards and Service Limits
Manual Transmission — Section 13
Main Menu
Table of Contents
Standards and Service Limits
⇀ Manual Transmission — Section 13
MEASUREMENT
STANDARD (NEW)
SERVICE LIMIT
Transmissron oil
Capacity E (US qt, lmn qt)
.0, 2.5) for overhaul
.9. 2.4) for oil change
Mainsha’t
Diameter of ball bearing contact area
(transmission housing sidel
30.984-31.000‹1.220-1.221i i
30.93 (1 ‚2177)
Diameter of needle hearing contact area 42384-43000 (169271.693) 42.93 (1.690)
Diameter of ball bearing contact area
(clutch housing side) 32002—32018 (1.2604261) 31.95 (1 ‚258)
Runout 0.02 (0.001) max. 0.05 (0,002)
4 End play 0.14-0.21 (GOOG-0,008) Adjust with a shim.
Mainshaft 3rd gear |.D. 49.00948025 (1.9295-1.9301) 1 4908 (1.9323)
End play ODE-0.21 (0.0020008) 0.3 (0.012)
Thickness 35.92-35.97 (1.414-1.416) 35.80 (1.409)
Mainshaft 4th gear |.D. 4900949.025 (1.9295-19301) 49.08 (1.9323)
End play CDG-0.21 (0.0020008) 0.3 (0.012)
Thickness w 35.926537 (1.414-1A16) 35.80 (1.409)
Mainshafl 5th gear |.D. 47009—47025 (18507—18514) 47.08 (1.8535)
End play 0.060,21 (0002—0008) 0.3 (0.012)
Thickness 34.92—34.97 (1375-1377) 34.80 (1.370)
Spacer collar |.D. 36.002-36012 [1.417-1A18) 36.06 (1.420)
(Malnsham 0D. 4th gear side 42989-43000 (1692») ‚693) 42.94 (1.691)
51h gear side 4198942.000 (1653-11354) 41 ‚94 (1.651)
Length 4th gear side 29.53-29.58 (1463-1165) 29.51 (1.162)
51h gear side 28.53-28.56 (1.123~1.125) 28.51 (1.122)
3-4
Manual Transmission — Section 13
Main Menu
Table of Contents
—— Manual Transmission — Section 13
Unit of length: mm (in)
5th/reverse shift piece)
Diameter (at the contact point with the shift forks and
11.9 — 12.0 (0.469 — 0,472)
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Countersheft Diameter of needle bearing contact area
(clutch housing side) 43.974 — 43.990 (1.731 — 1.732) 43.92 (1.729)
Diameter of needle ancl ball bearing contact area
(transmission housing side) 33.984 7 34.000 (1.338 71.339) 33.93 (1.336)
_ Runout 0.02 (0.001) max. 0.05 (0.002)
Countarshaft |.D. 60.510 – 60.529 (2.382 — 2.383) 60.58 (2.385)
1st gear End play (when tightened by the specified torque) 0.04 — 0.10 (0.002 — 0.004) Adjust with a washer.
Countershaft LD. 57.010-57.029 (2.244 —2.245) 57.08 (2.247) 7
2nd gear ¿nd play( (when trghtenedÿby the specified torque) 0.04 ⋅ 0.10 (0.002 — 0.004) Adjust with a collar.
Countershaft Diameter of needle bearing Contact area 54.487 – 54.500 (2.145 — 2.1451 − 54.43 (2.143) − “—
reverse gear
Spacer collar |.D. 43.046 – 43.056 (1.6947 — 1.6951) 43.10 (1.697)
(Counlershah) 0.0. i i V W 51.987 – 52.0001211467 — 2.0472) 51.94 (2.045)
Reverse idler gear O.D. 21.987 — 22.000 (0.8656 4.8661) 21.93 (0.8634)
shah
. -l– ‘- I i
Reverse driven LD. 28.007 — 20.020 (1.1026 71.1031) 28.07 (1.1051)
gear and reverse
drive gear
to“ pump Driven gear bassin—transmission housing clearance 0.3 — 0.8 (0.01 — 0.03) 0.9 (0.04)
Driven gear thickness 17.0 — 17.1 (0.669 — 0.673) 16.9 (0.665)
Inner-to70uter rotor radial clearance 0.14 (0.006) max. 0.20 (0.008)
Pump body—to-outer I’DlOl’ radial clearance 0.1 7 0.2 (0.004 – 0.008) 0.22 (0.009)
Pump bodytoctiter rotor side clearance 0.03 7 0.10 (0.001 — 0.004) 0.15 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.85 71.10(0.033 7 0.043) 0.4 (0016)
Dual cone Clearance (ring pushed against gear)
synchro ring Outer synchro ring-m-gear 0.95 7 1.68 (0.037 7 0.066) 0.6 (0.024)
Synchro conavlu~gear 0.5 — 1.0 (0.020 — 0.039) 0.3 (0.012)
Outer synchro ring-trrsynchro cone 0.5 — 1.0 (0.020 — 0.039) 0.3 (0.012)
Shift fork Finger thickness 1st/2nd shift fork 8.9 — 9.0 (0.350 — 0.354) ↼
?ard/Mh shift fork 7.4 — 7.5 (0.291 — 0.295) h`
5th shift fork 6.4 7 6.5 (0.252 — 0.256) —
Reverse shift fork 6.4 7 6.5 (0.252 — 0.256) vv-
J Fingervlo-synchrt) 5|вв\.е с|еагапсе 0.45 — 0.65 (0.018 7 0.025) 1.0 (0.039) 7
Reverse shift arm Arm—to—Sth/reverse shift piece clearance 0.05 7 0.30 (0.002 — 0.012) 0.5 (0.02)
Groove width 7.05 — 7.20 (0.278 — 0.283)
Arm-torreverse shift fork clearance 0.05 — 0.35 (0.002 — 0.014) 0.5 (0.02)
Diameter
(at the contact point wirh the reverse shift fork) 12.8 — 13.0 (0.504 — 0.512)
“sninÎnÏ ` ` ⊽ Arm7to7shih piece clearance 0.05 — 0.25 (0.002 – 0.010) 0.5 (0.02)
Diameter (at the contact point with the shift piece) 12.5 — 13.0 (0.508 — 0.512)
Interlock lnterlocknoeselect arm clearance 0.03 7 0.15 (0.001 — 0.005) —
Diameter (at the contact point with the select arm) 11.95 — 12.00 (0.470 — 0.472) —
Shift piece Shift piece-!oshin forkz; and 5th/reverse shift piece
clearance 0.2 7 0.5 (0.008 7 0.020) 0.6 (0.024)
Manual Transmission — Section 13
Main Menu
Table of Contents
Standards and Service Limits
⇀ Manual Transmission — Section 13
MEASUREMENT
STANDARD (NEW)
SERVICE LIMIT
Transmissron oil
Capacity E (US qt, lmn qt)
.0, 2.5) for overhaul
.9. 2.4) for oil change
Mainsha’t
Diameter of ball bearing contact area
(transmission housing sidel
30.984-31.000‹1.220-1.221i i
30.93 (1 ‚2177)
Diameter of needle hearing contact area 42384-43000 (169271.693) 42.93 (1.690)
Diameter of ball bearing contact area
(clutch housing side) 32002—32018 (1.2604261) 31.95 (1 ‚258)
Runout 0.02 (0.001) max. 0.05 (0,002)
4 End play 0.14-0.21 (GOOG-0,008) Adjust with a shim.
Mainshaft 3rd gear |.D. 49.00948025 (1.9295-1.9301) 1 4908 (1.9323)
End play ODE-0.21 (0.0020008) 0.3 (0.012)
Thickness 35.92-35.97 (1.414-1.416) 35.80 (1.409)
Mainshaft 4th gear |.D. 4900949.025 (1.9295-19301) 49.08 (1.9323)
End play CDG-0.21 (0.0020008) 0.3 (0.012)
Thickness w 35.926537 (1.414-1A16) 35.80 (1.409)
Mainshafl 5th gear |.D. 47009—47025 (18507—18514) 47.08 (1.8535)
End play 0.060,21 (0002—0008) 0.3 (0.012)
Thickness 34.92—34.97 (1375-1377) 34.80 (1.370)
Spacer collar |.D. 36.002-36012 [1.417-1A18) 36.06 (1.420)
(Malnsham 0D. 4th gear side 42989-43000 (1692») ‚693) 42.94 (1.691)
51h gear side 4198942.000 (1653-11354) 41 ‚94 (1.651)
Length 4th gear side 29.53-29.58 (1463-1165) 29.51 (1.162)
51h gear side 28.53-28.56 (1.123~1.125) 28.51 (1.122)
3-4
Manual Transmission — Section 13
Main Menu
Table of Contents
—— Manual Transmission — Section 13
Unit of length: mm (in)
5th/reverse shift piece)
Diameter (at the contact point with the shift forks and
11.9 — 12.0 (0.469 — 0,472)
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Countersheft Diameter of needle bearing contact area
(clutch housing side) 43.974 — 43.990 (1.731 — 1.732) 43.92 (1.729)
Diameter of needle ancl ball bearing contact area
(transmission housing side) 33.984 7 34.000 (1.338 71.339) 33.93 (1.336)
_ Runout 0.02 (0.001) max. 0.05 (0.002)
Countarshaft |.D. 60.510 – 60.529 (2.382 — 2.383) 60.58 (2.385)
1st gear End play (when tightened by the specified torque) 0.04 — 0.10 (0.002 — 0.004) Adjust with a washer.
Countershaft LD. 57.010-57.029 (2.244 —2.245) 57.08 (2.247) 7
2nd gear ¿nd play( (when trghtenedÿby the specified torque) 0.04 ⋅ 0.10 (0.002 — 0.004) Adjust with a collar.
Countershaft Diameter of needle bearing Contact area 54.487 – 54.500 (2.145 — 2.1451 − 54.43 (2.143) − “—
reverse gear
Spacer collar |.D. 43.046 – 43.056 (1.6947 — 1.6951) 43.10 (1.697)
(Counlershah) 0.0. i i V W 51.987 – 52.0001211467 — 2.0472) 51.94 (2.045)
Reverse idler gear O.D. 21.987 — 22.000 (0.8656 4.8661) 21.93 (0.8634)
shah
. -l– ‘- I i
Reverse driven LD. 28.007 — 20.020 (1.1026 71.1031) 28.07 (1.1051)
gear and reverse
drive gear
to“ pump Driven gear bassin—transmission housing clearance 0.3 — 0.8 (0.01 — 0.03) 0.9 (0.04)
Driven gear thickness 17.0 — 17.1 (0.669 — 0.673) 16.9 (0.665)
Inner-to70uter rotor radial clearance 0.14 (0.006) max. 0.20 (0.008)
Pump body—to-outer I’DlOl’ radial clearance 0.1 7 0.2 (0.004 – 0.008) 0.22 (0.009)
Pump bodytoctiter rotor side clearance 0.03 7 0.10 (0.001 — 0.004) 0.15 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.85 71.10(0.033 7 0.043) 0.4 (0016)
Dual cone Clearance (ring pushed against gear)
synchro ring Outer synchro ring-m-gear 0.95 7 1.68 (0.037 7 0.066) 0.6 (0.024)
Synchro conavlu~gear 0.5 — 1.0 (0.020 — 0.039) 0.3 (0.012)
Outer synchro ring-trrsynchro cone 0.5 — 1.0 (0.020 — 0.039) 0.3 (0.012)
Shift fork Finger thickness 1st/2nd shift fork 8.9 — 9.0 (0.350 — 0.354) ↼
?ard/Mh shift fork 7.4 — 7.5 (0.291 — 0.295) h`
5th shift fork 6.4 7 6.5 (0.252 — 0.256) —
Reverse shift fork 6.4 7 6.5 (0.252 — 0.256) vv-
J Fingervlo-synchrt) 5|вв\.е с|еагапсе 0.45 — 0.65 (0.018 7 0.025) 1.0 (0.039) 7
Reverse shift arm Arm—to—Sth/reverse shift piece clearance 0.05 7 0.30 (0.002 — 0.012) 0.5 (0.02)
Groove width 7.05 — 7.20 (0.278 — 0.283)
Arm-torreverse shift fork clearance 0.05 — 0.35 (0.002 — 0.014) 0.5 (0.02)
Diameter
(at the contact point wirh the reverse shift fork) 12.8 — 13.0 (0.504 — 0.512)
“sninÎnÏ ` ` ⊽ Arm7to7shih piece clearance 0.05 — 0.25 (0.002 – 0.010) 0.5 (0.02)
Diameter (at the contact point with the shift piece) 12.5 — 13.0 (0.508 — 0.512)
Interlock lnterlocknoeselect arm clearance 0.03 7 0.15 (0.001 — 0.005) —
Diameter (at the contact point with the select arm) 11.95 — 12.00 (0.470 — 0.472) —
Shift piece Shift piece-!oshin forkz; and 5th/reverse shift piece
clearance 0.2 7 0.5 (0.008 7 0.020) 0.6 (0.024)