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Service Data

Transaxle case oil seal LH driven in depth 3.0 to 4.0 mm (0.118 to 0.157 in.)
Transaxle case cover oil seal RH drive in depth - 0.5 to 0.5 mm (- 0.020 to 0.020 in.)
Manual transaxle unit
5th gear thrust clearance Standard clearance 0.10 to 0.57 mm (0.0039 to 0.0224 in.)
5th gear radial clearance Standard clearance 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
Reverse idler gear sub-assembly inside diameter Standard inside diameter 20.056 to 20.074 mm (0.7896 to 0.7903 in.)
Maximum inside diameter 20.074 mm (0.7903 in.)
Reverse idler gear shaft outside diameter Standard outside diameter 19.984 to 20.000 mm (0.7868 to 0.7874 in.)
Minimum outside diameter 19.984 mm (0.7868 in.)
No. 3 transmission hub sleeve groove - thickness of the claw part on No. 3 gear gear shift fork Standard clearance 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
5th gear inside diameter Standard inside diameter 34.981 to 34.997 mm (1.3772 to 1.3778 in.)
Maximum inside diameter 34.997 mm (1.3778 in.)
Output shaft rear bearing clearance 3.8 to 4.4 mm (0.150 to 0.173 in.)
Output shaft bearing preload New bearing 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf)
Used bearing 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf)
Output shaft rear bearing shim thickness 0 1.30 mm (0.0512 in.)
1 1.35 mm (0.0531 in.)
2 1.40 mm (0.0551 in.)
3 1.45 mm (0.0571 in.)
4 1.50 mm (0.0591 in.)
5 1.55 mm (0.0610 in.)
6 1.60 mm (0.0630 in.)
7 1.65 mm (0.0650 in.)
8 1.70 mm (0.0669 in.)
9 1.75 mm (0.0689 in.)
A 1.80 mm (0.0709 in.)
B 1.85 mm (0.0728 in.)
C 1.90 mm (0.0748 in.)
D 1.95 mm (0.0768 in.)
E 2.00 mm (0.0787 in.)
F 2.05 mm (0.0807 in.)
G 2.10 mm (0.0827 in.)
H 2.15 mm (0.0846 in.)
J 2.20 mm (0.0866 in.)
K 2.25 mm (0.0886 in.)
L 2.30 mm (0.0906 in.)
M 2.35 mm (0.0925 in.)
N 2.40 mm (0.0945 in.)
P 2.45 mm (0.0965 in.)
Q 2.50 mm (0.0984 in.)
Front differential case tapered roller bearing preload New bearing 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf)
Used bearing 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf)
Front differential case shim REAR thickness 0 2.00 mm (0.0787 in.)
1 2.05 mm (0.0807 in.)
2 2.10 mm (0.0827 in.)
3 2.15 mm (0.0846 in.)
4 2.20 mm (0.0866 in.)
5 2.25 mm (0.0886 in.)
6 2.30 mm (0.0906 in.)
7 2.35 mm (0.0925 in.)
8 2.40 mm (0.0945 in.)
9 2.45 mm (0.0965 in.)
A 2.50 mm (0.0984 in.)
B 2.55 mm (0.1004 in.)
C 2.60 mm (0.1024 in.)
D 2.65 mm (0.1043 in.)
E 2.70 mm (0.1063 in.)
F 2.75 mm (0.1083 in.)
G 2.80 mm (0.1102 in.)
H 2.85 mm (0.1122 in.)
Front differential case oil seal clearance 1 to 2 mm (0.039 to 0.079 in.)
Input shaft front bearing clearance 4.28 to 4.60 mm (0.1685 to 0.1811 in.)
Reverse restrict pin clearance 12.5 to 13.5 mm (0.492 to 0.531 in.)
No. 3 transmission clutch hub snap ring clearance 0.1 mm or less (0.004 in. or less)
No. 3 transmission clutch hub snap ring thickness a 1.75 to 1.80 mm (0.0689 to 0.0709 in.)
b 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
c 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
d 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
e 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
f 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
g 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
h 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
j 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
Input shaft assembly
4th gear thrust clearance Standard clearance 0.10 to 0.57 mm (0.0039 to 0.0224 in.)
3rd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
4th gear radical clearance JTEKT made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)
3rd gear radical clearance JTEKT made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)
Input shaft run out Maximum run out 0.03 mm (0.0012 in.)
Input shaft standard outside diameter A 35.984 to 36.000 mm (1.4167 to 1.4173 in.)
B 35.984 to 36.000 mm (1.4167 to 1.4173 in.)
C 27.957 to 27.972 mm (1.1007 to 1.1013 in.)
Input shaft minimum outside diameter A 35.984 mm (1.4167 in.)
B 35.984 mm (1.4167 in.)
C 27.957 mm (1.1007 in.)
4th gear inside diameter Standard inside diameter 42.009 to 42.025 mm (1.6539 to 1.6545 in.)
Maximum inside diameter 42.025 mm (1.6545 in.)
3rd gear inside diameter Standard inside diameter 43.009 to 43.025 mm (1.6933 to 1.6939 in.)
Maximum inside diameter 43.025 mm (1.6939 in.)
Between the 4th gear spline end and synchronizer outer ring back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.)
Between the 3rd gear spline end and synchronizer outer ring back clearance 0.65 to 1.75 mm (0.0256 to 0.0689 in.)
No. 2 transmission hub sleeve groove - thickness of the claw part on No. 2 gear shift fork Standard clearance 0.11 to 0.69 mm (0.0043 to 0.0272 in.)
No. 2 transmission clutch hub snap ring clearance Standard clearance 0.1 mm or less (0.004 in. or less)
Transmission clutch hub No. 2 snap ring thickness H 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
J 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
K 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
L 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
M 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
N 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
P 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
Input shaft rear radical ball bearing snap ring clearance Standard clearance 0.1 mm or less (0.004 in. or less)
Input shaft rear radical ball bearing snap ring thickness 1 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
2 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
3 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
4 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
5 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
6 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
7 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
8 2.70 to 2.75 mm (0.1063 to 0.1083 in.)
Output shaft assembly
1st gear thrust clearance Standard clearance 0.25 to 0.40 mm (0.0098 to 0.0157 in.)
2nd gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
1st gear radical clearance JTEKT made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)
2nd gear radical clearance JTEKT made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)
Output shaft run out Maximum run out 0.03 mm (0.0012 in.)
Output shaft standard outside diameter A 32.010 to 32.026 mm (1.2602 to 1.2609 in.)
B 44.984 to 45.000 mm (1.7710 to 1.7717 in.)
C 28.010 to 28.023 mm (1.1028 to 1.1033 in.)
Output shaft minimum outside diameter A 32.010 mm (1.2602 in.)
B 44.984 mm (1.7710 in.)
C 28.010 mm (1.1028 in.)
2nd gear inside diameter Standard inside diameter 50.009 to 50.025 mm (1.9689 to 1.9695 in.)
Maximum inside diameter 50.025 mm (1.9695 in.)
1st gear inside diameter Standard inside diameter 51.009 to 51.025 mm (2.0082 to 2.0089 in.)
Maximum inside diameter 51.025 mm (2.0089 in.)
Between the 2nd gear and No. 2 synchronizer ring back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.)
Between the 1st gear and No. 1 synchronizer ring set back clearance 0.70 to 1.45 mm (0.0276 to 0.0571 in.)
Reverse gear groove - thickness of the claw part on No. 1 gear shift fork clearance Standard clearance 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
Shift and select lever shaft assembly
Control shaft cover oil oil seal drive in depth 28 to 29 mm (1.1024 to 1.1417 in.)
Shift lever slotted pin clearance to the No. 1 shift lever inner - 0.4 to 0.6 mm (- 0.0158 to 0.0236 in.)
Shift lever slotted pin clearance to the No. 2 shift lever inner 0.7 to 1.7 mm (0.0276 to 0.0669 in.)
Differential case assembly
Front differential side gear backlash Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Front differential pinion thrust washer thickness Minimum thickness 0.9 mm (0.035 in.)
Front differential pinion No. 1 shaft thickness Minimum diameter 17.975 mm (0.7077 in.)
Front differential side gear backlash Standard backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Front differential side gear thrust washer thickness 1 1.00 mm (0.0394 in.)
2 1.10 mm (0.0433 in.)
3 1.20 mm (0.0472 in.)
4 1.30 mm (0.0512 in.)
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