Manual Transmission and M/T Differential
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Transmission fluid | Capacity | Fluid change | 1.9 L (2.0 US qt) | - |
| Overhaul | 2.0 L (2.1 US qt) | - | ||
| Fluid type | Use Honda MTF. | |||
| Mainshaft | Thrust clearance | 0.14-0.21 mm (0.0055-0.0083 in) | Adjust | |
| Diameter of crankshaft pilot bushing contact area | 20.80-20.85 mm (0.8189-0.8209 in) | 20.80 mm (0.8189 in) | ||
| Diameter of ball bearing contact area (clutch housing side) | 28.002-28.015 mm (1.10244-1.10295 in) | 28.002 mm (1.10244 in) | ||
| Diameter of needle bearing contact area | 41.984-42.000 mm (1.65291-1.65354 in) | 41.984 mm (1.65291 in) | ||
| Diameter of ball bearing contact area (transmission housing side) | 30.984-31.000 mm (1.21984-1.22047 in) | 30.984 mm (1.21984 in) | ||
| Diameter of 4th/5th gear distance collar contact area | 35.984-36.000 mm (1.41669-1.41732 in) | 35.984 mm (1.41669 in) | ||
| Diameter of 6th gear distance collar contact area | 32.984-33.000 mm (1.29858-1.29921 in) | 32.984 mm (1.29858 in) | ||
| Runout | 0.02 mm (0.0008 in) max. | - | ||
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Mainshaft 2nd, 3rd, 4th, 5th, 6th gears | Clearance | 2nd-3rd | 0.06-0.16 mm (0.003-0.006 in) | 0.16 mm (0.006 in) |
| 4th-4th/5th gear distance collar | 0.06-0.16 mm (0.0024-0.0063 in) | 0.16 mm (0.0063 in) | ||
| 5th-4th/5th gear distance collar | 0.06-0.16 mm (0.0024-0.0063 in) | 0.16 mm (0.0063 in) | ||
| 6th-ball bearing | 0.06-0.16 mm (0.0024-0.0063 in) | 0.16 mm (0.0063 in) | ||
| Thickness | 3rd | 23.92-23.97 mm (0.9417-0.9437 in) | 23.92 mm (0.9417 in) | |
| 4th, 5th | 22.42-22.47 mm (0.8827-0.8846 in) | 22.42 mm (0.8827 in) | ||
| 6th | 26.92-26.97 mm (1.0598-1.0618 in) | 26.92 mm (1.0598 in) | ||
| Mainshaft 4th/5th gear distance collar | Length | 4th/5th | 22.53-22.58 mm (0.8870-0.8890 in) | - |
| Mainshaft 6th gear distance collar | Length | 27.03-27.08 mm (1.0642-1.0661 in) | - | |
| Countershaft | Diameter of needle bearing contact area (clutch housing side) | 40.000-40.015 mm (1.57480-1.57539 in) | 40.000 mm (1.57480 in) | |
| Diameter of ball bearing contact area (transmission housing side) | 30.002-30.015 mm (1.18118-1.18169 in) | 30.002 mm (1.18118 in) | ||
| Diameter of 2nd gear distance collar contact area | 42.937-42.950 mm (1.69043-1.69094 in) | 42.937 mm (1.69043 in) | ||
| Diameter of countershaft reverse gear contact area | 42.975-42.991 mm (1.69193-1.69256 in) | 42.975 mm (1.69193 in) | ||
| Runout | 0.02 mm (0.0008 in) max. | - | ||
| 35 mm shim-to-bearing inner race clearance | 0.04-0.10 mm (0.002-0.003 in) | Adjust | ||
| Countershaft reverse, 1st, 2nd, 3rd gears | Clearance | 1st-countershaft reverse gear | 0.06-0.16 mm (0.0024-0.0063 in) | 0.16 mm (0.0063 in) |
| 2nd-3rd | 0.06-0.21 mm (0.003-0.008 in) | 0.21 mm (0.008 in) | ||
| Thickness | 1st | 23.92-23.97 mm (0.9417-0.9437 in) | 23.92 mm (0.9417 in) | |
| 2nd | 29.42-29.47 mm (1.1583-1.1602 in) | 29.42 mm (1.1583 in) | ||
| Countershaft reverse gear | Length | 32.05-32.15 mm (1.2618-1.2657 in) | - | |
| Countershaft 2nd gear distance collar | Length | 26.53-26.58 mm (1.0445-1.0465 in) | - |
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Synchro ring | Ring-to-gear clearance (ring pushed against gear) | 0.70-1.49 mm (0.028-0.058 in) | 0.70 mm (0.028 in) | |
| Double cone synchro and triple cone synchro | Outer synchro ring-to-synchro cone clearance (ring pushed against gear) | 0.70-1.19 mm (0.028-0.046 in) | 0.70 mm (0.028 in) | |
| Synchro cone-to-gear clearance (ring pushed against gear) | 0.50-1.04 mm (0.020-0.040 in) | 0.50 mm (0.020 in) | ||
| Outer synchro ring-to-gear clearance (ring pushed against gear) | 0.95-1.68 mm (0.038-0.066 in) | 0.95 mm (0.038 in) | ||
| Shift fork | Finger thickness | 1st/2nd, 3rd/4th, 5th/6th | 7.45-7.55 mm (0.2933-0.2972 in) | - |
| Reverse | 6.25-6.35 mm (0.2461-0.2500 in) | - | ||
| Fork-to-synchro sleeve clearance | 0.4-0.6 mm (0.02 in) | 0.6 mm (0.02 in) | ||
| Reverse shift lever | Finger width | 6.75-7.00 mm (0.2657-0.2756 in) | - | |
| Reverse shift lever width at contact area (reverse shift piece side) | 17.0-17.2 mm (0.669-0.677 in) | - | ||
| Reverse shift lever-to-reverse shift piece clearance | 0-0.4 mm (0-0.01 in) | 0.4 mm (0.01 in) | ||
| Reverse shift lever-to-reverse shift fork clearance | 0.40-0.85 mm (0.016-0.033 in) | 0.85 mm (0.033 in) | ||
| Detent ball spring | Free length | 1st/2nd, 3rd/4th, 5th/6th | 26.0 mm (1.024 in) | When worn or damaged |
| Reverse shift fork | 26.0 mm (1.024 in) | When worn or damaged | ||
| Select arm | 26.0 mm (1.024 in) | When worn or damaged | ||
| Shift arm | 23.4 mm (0.921 in) | When worn or damaged | ||
| Steel ball | Ball size | 7.94 mm (0.3126 in) | When worn or damaged | |
| Shift arm | Shift arm width at contact area | 13.8-14.0 mm (0.543-0.551 in) | - | |
| Shift arm-to-shift piece clearance | 0-0.4 mm (0-0.01 in) | 0.4 mm (0.01 in) | ||
| Shift piece | Shift fork width at contact area | 15.9-16.0 mm (0.626-0.630 in) | - | |
| Shift piece-to-shift fork clearance | 0.2-0.5 mm (0.01-0.02 in) | 0.5 mm (0.02 in) | ||
| Select arm | Interlock width at contact area | 13.9-14.0 mm (0.547-0.551 in) | - | |
| Select arm-to-interlock clearance | 0.01-0.21 mm (0.001-0.008 in) | 0.21 mm (0.008 in) | ||
| M/T differential carrier | Backlash | 0.05-0.15 mm (0.0020-0.0059 in) | - | |
| M/T differential 90 mm shim | 90 mm shim-to-bearing outer race clearance in transmission housing | 0-0.10 mm (0-0.003 in) | Adjust |