Standards and Service Limits
Manual Transmission — Section 13
Main Menu
Table of Contents
Standards and Service Limits
— Manual Transmission — Section 13
gear
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Transmission oil Capacity! (US qt. Imp qt) 2.8 (3.0, 2.5) for overhaul
2.7 (2.9, 2.4) for oil change
Mainshaft Diameter of hall hearing contact area
(transmission housing side) 30984-231000 (1 .ZZO-1.221) 30.93 (1.2177)
Diameter of needle hearing contact area 4238443.000 (1592-1693) 42.93 (1.690)
Diameter of ball bearing contact area
(clutch housing side) 32.00232018 (1160—1261) 31.95 (1.258)
Hunout 0.02 (0.001) max. 0.05 (0.002)
End play 0.14-0.21 (0006-0008) Adjust with a shim.
Mainshaft 3rd gear I.D. 49.009-49025 (19295-19301) 49.08 (1.9323)
End play 0.06-0.21 (0002-0008) 0.3 [0.012)
Thickness 35.92-35.97 [1.414-1.415) 35.80 (1.409)
Mainshafi 4th gear I.D. 49009-49025 (13295-18301) 49.08 (1.9323)
End play ODE-0.21 (0.002-0008) 0.3 (0.012)
Thickness 35.92-35.97 (1.414—1.416) 35.80 (1.409)
Mainshaft 5th gear LD. 47.009-47025 (1.8507413514) 47.08 (1.8535)
End play 0.06-0.21 [0002-0008) 0.3 (0.012)
Thickness 34.92-34.97 (1.375-1.377) 34.80 (1.370)
Spacer collar I.D. 36.002—36012 (1.417-1.418) 36.06 (1.420)
(Mainshaft) 0.0. 4th gear side 42989-43000 (1592-1693) 42.94 (1.691)
5th gear side 4198942.000 (1.653-1554) 41.94 (1.651)
Length 4th gear side 29.53—29.58 (1.163-1.165) 29.51 (1.162)
5th gear side 28.532858 (1.123-1.125) 28.51 (1.122)
Countershaft Diameter of needle hearing contact area
(clutch housing side) 43.974-43990 (1.731-1.732) 43.92 (1.729)
Diameter of needle and ball hearing contact
area (transmission housing side) 33.984~34.000 (1338-1339) 33.93 (1.336)
Runout 0.02 (0.001) max. 0.05 (0.002)
Countershaft ⇃⋅∣⊃⋅ ⊖∘−⊟↿∘⋉∂∘⋅⋮≳∋ ∢⊋⋅∂≨≅⊓⋅⊰⊟⊰∣ 60.58 (2.385)
1st gear End play (when tightened by the specrfled 0040_10 (0,0020004) Adjust With a
torque) washer.
Countershaft LD. 57.010-57.029 (2244-2245) 57.08 (2.247)
2nd gea’ 52125:” ‘When “gmened by ‘he зрите” 0.04.0.10 (0.0020004) Adjust with a collar.
Countershaft Diameter of needle bearing contact area 54.487-54.500 (2145-2146) 54.43 (2.143)
reverse gear
Spacer collar LD. 43.046-43056 (1.6947-1.6951) 43.10 (1.697)
(Countershaft) O.D. 51 .987—52.000 (20467720472) 51.94 (2.045)
⋮∏⊦⇡≟∣∱⊖⇡↾⊟⊖ ⋮⊔∣⊖↾ gea’ 0.0. 21.987-22000 ¡0.865608661) 21.93 (0.8634)
Reverse driven gear
and reverse drive I.D. 28007-28020 (1.1026-1.1031) 28.07 (1.1051)
3-6
Manual Transmission — Section 13
Main Menu
Table of Contents
ì Manual Transmission — Section 13
Unit of length: mm (in)
Diameter (at the contact point with the shift forks and
Eth/reverse shift piece)
11.9-120 (CASS-0.472)
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Oil pump Driven gear bosem-transmission housing clearance 0.3—0.8 (001-003) 0.9 (0.04)
Driven gear thickness 17.0-17.1 (0669-0673) 16.9 (0.665)
Innerrtorouter rotor radial clearance 0.14 (0006) max. 0.20 (0.008)
Pump body-to-outer rotor radial clearance 0.1-0.2 (0004-0008) 0.22 (0.009)
Pump bodyrtovouter rotor side clearance 0.03-0.10 (0001-0004) 0.15 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.85-1.10 (0033-0043) 0.4 (0.015)
Dual cone Clearance (ring pushed against gear)
synchro ring Outer synchro ring-to-gear 0.95-1.68 (0037-0066) 0.6 (0.024)
Synchro cone-to-gear 0.5-1.0 (0020-0039) 03 (0.012)
Outer synchro ring-to-synchro cone 0.5-1.0 (0020-0039) 0.3 (0.012)
Shift fork Finger thickness ist/2nd shift fork 8.9-9.0 (0350-0354) v
3rd/4th shift fork 7.4-7.5 (0291-0295) —
5th shift fork 6.4-6.5 (0152-0156) —
Reverse shift fork 6.4—6.5 (0252-02561 —
Finger-tovsynchro sleeve clearance 0,45-0,65 (0018-0026) 1.0 (0.039)
Reverse shift arm Arm-to-Sth/reverse shift piece clearance 0.05-0.30 (0002-0012) 0.5 (0.02)
Groove width 7.05-7.20 (0278-0283) —
Arm-to-reverse shift fork clearance 0.05035 (0002-0014) 0.5 (0.02)
Diameter
(at the contact point with the reverse shift fork) 12.8-130 10.5040512) –
Shift arm Arm-(o-shift piece clearance ODB-0.25 (0002-0010) 0.5 (0.02)
Diameter (at the contact point with the shift piece) 12.9-13.0 (0508-0512) i _
Interlock Interlock-to-select arm clearance 0.03-0.15 (0001-0006) —
Diameter (at the contact point with the select arm) 11.95-12.00 (0.470-O.472) — _
Shift piece Shift piece-to-shift forks and 5th/reverse shift piece
clearance 0.2-0.5 (0008-0020) 0.6 (0.024)
3-7
Manual Transmission — Section 13
Main Menu
Table of Contents
Standards and Service Limits
— Manual Transmission — Section 13
gear
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Transmission oil Capacity! (US qt. Imp qt) 2.8 (3.0, 2.5) for overhaul
2.7 (2.9, 2.4) for oil change
Mainshaft Diameter of hall hearing contact area
(transmission housing side) 30984-231000 (1 .ZZO-1.221) 30.93 (1.2177)
Diameter of needle hearing contact area 4238443.000 (1592-1693) 42.93 (1.690)
Diameter of ball bearing contact area
(clutch housing side) 32.00232018 (1160—1261) 31.95 (1.258)
Hunout 0.02 (0.001) max. 0.05 (0.002)
End play 0.14-0.21 (0006-0008) Adjust with a shim.
Mainshaft 3rd gear I.D. 49.009-49025 (19295-19301) 49.08 (1.9323)
End play 0.06-0.21 (0002-0008) 0.3 [0.012)
Thickness 35.92-35.97 [1.414-1.415) 35.80 (1.409)
Mainshafi 4th gear I.D. 49009-49025 (13295-18301) 49.08 (1.9323)
End play ODE-0.21 (0.002-0008) 0.3 (0.012)
Thickness 35.92-35.97 (1.414—1.416) 35.80 (1.409)
Mainshaft 5th gear LD. 47.009-47025 (1.8507413514) 47.08 (1.8535)
End play 0.06-0.21 [0002-0008) 0.3 (0.012)
Thickness 34.92-34.97 (1.375-1.377) 34.80 (1.370)
Spacer collar I.D. 36.002—36012 (1.417-1.418) 36.06 (1.420)
(Mainshaft) 0.0. 4th gear side 42989-43000 (1592-1693) 42.94 (1.691)
5th gear side 4198942.000 (1.653-1554) 41.94 (1.651)
Length 4th gear side 29.53—29.58 (1.163-1.165) 29.51 (1.162)
5th gear side 28.532858 (1.123-1.125) 28.51 (1.122)
Countershaft Diameter of needle hearing contact area
(clutch housing side) 43.974-43990 (1.731-1.732) 43.92 (1.729)
Diameter of needle and ball hearing contact
area (transmission housing side) 33.984~34.000 (1338-1339) 33.93 (1.336)
Runout 0.02 (0.001) max. 0.05 (0.002)
Countershaft ⇃⋅∣⊃⋅ ⊖∘−⊟↿∘⋉∂∘⋅⋮≳∋ ∢⊋⋅∂≨≅⊓⋅⊰⊟⊰∣ 60.58 (2.385)
1st gear End play (when tightened by the specrfled 0040_10 (0,0020004) Adjust With a
torque) washer.
Countershaft LD. 57.010-57.029 (2244-2245) 57.08 (2.247)
2nd gea’ 52125:” ‘When “gmened by ‘he зрите” 0.04.0.10 (0.0020004) Adjust with a collar.
Countershaft Diameter of needle bearing contact area 54.487-54.500 (2145-2146) 54.43 (2.143)
reverse gear
Spacer collar LD. 43.046-43056 (1.6947-1.6951) 43.10 (1.697)
(Countershaft) O.D. 51 .987—52.000 (20467720472) 51.94 (2.045)
⋮∏⊦⇡≟∣∱⊖⇡↾⊟⊖ ⋮⊔∣⊖↾ gea’ 0.0. 21.987-22000 ¡0.865608661) 21.93 (0.8634)
Reverse driven gear
and reverse drive I.D. 28007-28020 (1.1026-1.1031) 28.07 (1.1051)
3-6
Manual Transmission — Section 13
Main Menu
Table of Contents
ì Manual Transmission — Section 13
Unit of length: mm (in)
Diameter (at the contact point with the shift forks and
Eth/reverse shift piece)
11.9-120 (CASS-0.472)
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Oil pump Driven gear bosem-transmission housing clearance 0.3—0.8 (001-003) 0.9 (0.04)
Driven gear thickness 17.0-17.1 (0669-0673) 16.9 (0.665)
Innerrtorouter rotor radial clearance 0.14 (0006) max. 0.20 (0.008)
Pump body-to-outer rotor radial clearance 0.1-0.2 (0004-0008) 0.22 (0.009)
Pump bodyrtovouter rotor side clearance 0.03-0.10 (0001-0004) 0.15 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.85-1.10 (0033-0043) 0.4 (0.015)
Dual cone Clearance (ring pushed against gear)
synchro ring Outer synchro ring-to-gear 0.95-1.68 (0037-0066) 0.6 (0.024)
Synchro cone-to-gear 0.5-1.0 (0020-0039) 03 (0.012)
Outer synchro ring-to-synchro cone 0.5-1.0 (0020-0039) 0.3 (0.012)
Shift fork Finger thickness ist/2nd shift fork 8.9-9.0 (0350-0354) v
3rd/4th shift fork 7.4-7.5 (0291-0295) —
5th shift fork 6.4-6.5 (0152-0156) —
Reverse shift fork 6.4—6.5 (0252-02561 —
Finger-tovsynchro sleeve clearance 0,45-0,65 (0018-0026) 1.0 (0.039)
Reverse shift arm Arm-to-Sth/reverse shift piece clearance 0.05-0.30 (0002-0012) 0.5 (0.02)
Groove width 7.05-7.20 (0278-0283) —
Arm-to-reverse shift fork clearance 0.05035 (0002-0014) 0.5 (0.02)
Diameter
(at the contact point with the reverse shift fork) 12.8-130 10.5040512) –
Shift arm Arm-(o-shift piece clearance ODB-0.25 (0002-0010) 0.5 (0.02)
Diameter (at the contact point with the shift piece) 12.9-13.0 (0508-0512) i _
Interlock Interlock-to-select arm clearance 0.03-0.15 (0001-0006) —
Diameter (at the contact point with the select arm) 11.95-12.00 (0.470-O.472) — _
Shift piece Shift piece-to-shift forks and 5th/reverse shift piece
clearance 0.2-0.5 (0008-0020) 0.6 (0.024)
3-7