Manual Transmission and M/T Differential
MANUAL TRANSMISSION AND M/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Manual transmission fluid | Capacity Use Honda MTF | Fluid change | 1.90 L (2.0 US qt) | |
| 2WD: overhaul | 2.15 L (2.3 US qt) | |||
| 4WD: overhaul | 2.25 L (2.4 US qt) | |||
| Mainshaft | End play | - | 0.11-0.17 mm (0.004-0.007 in.) | Adjust |
| Diameter of bushing contact area | - | 20.80-20.85 mm (0.8189-0.8209 in.) | 20.75 mm (0.817 in.) | |
| Diameter of distance collar contact area | - | 31.984-32.000 mm (1.2594-1.2598 in.) | 31.93 mm (1.257 in.) | |
| Diameter of ball bearing contact area (clutch housing side) | - | 27.977-27.990 mm (1.1015-1.1020 in.) | 27.94 mm (1.100 in.) | |
| Diameter of needle bearing contact area | - | 38.984-39.000 mm (1.5348-1.5354 in.) | 38.93 mm (1.533 in.) | |
| Diameter of ball bearing contact area (transmission housing side) | - | 27.987-28.000 mm (1.1019-1.1024 in.) | 27.94 mm (1.100 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| Mainshaft 3rd, 4th, and 5th gear | I.D. | - | 44.009-44.025 mm (1.7326-1.7333 in.) | 44.08 mm (1.735 in.) |
| End play | - | 0.06-0.16 mm (0.002-0.006 in.) | 0.25 mm (0.010 in.) | |
| Thickness | - | 23.92-23.97 mm (0.941-0.944 in.) | 23.80 mm (0.937 in.) | |
| Mainshaft 4th and 5th gear distance collar | I.D. | - | 32.00-32.01 mm (1.2598-1.2602 in.) | 32.02 mm (1.261 in.) |
| O.D. | - | 38.989-39.000 mm (1.5350-1.5354 in.) | 38.94 mm (1.533 in.) | |
| Length | A | 51.95-52.05 mm (2.045-2.049 in.) | - | |
| B | 24.03-24.08 mm (0.946-0.948 in.) | - | ||
| MBS distance collar | I.D. | - | 28.00-28.01 mm (1.102-1.103 in.) | 28.02 mm (1.103 in.) |
| Length | - | 23.95-24.05 mm (0.943-0.947 in.) | - | |
| Countershaft | Diameter of needle bearing contact area (clutch housing side) | - | 35.000-35.015 mm (1.3780-1.3785 in.) | 34.95 mm (1.376 in.) |
| Diameter of distance collar contact area | - | 39.937-39.950 mm (1.5723-1.5728 in.) | 39.88 mm (1.570 in.) | |
| Diameter of ball bearing contact area (transmission housing side) | - | 30.020-30.033 mm (1.1819-1.1824 in.) | 29.97 mm (1.180 in.) | |
| Runout | - | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | |
| 35 mm shim-to-bearing inner race clearance | - | 0.04-0.10 mm (0.0016-0.0039 in.) | Adjust | |
| Countershaft 1st gear | I.D. | - | 52.010-52.029 mm (2.0476-2.0484 in.) | 52.08 mm (2.050 in.) |
| End play | - | 0.06-0.16 mm (0.002-0.006 in.) | 0.25 mm (0.010 in.) | |
| Thickness | - | 22.92-22.97 mm (0.902-0.904 in.) | 22.87 mm (0.900 in.) | |
| Countershaft 2nd gear | I.D. | - | 52.010-52.029 mm (2.0476-2.0484 in.) | 52.08 mm (2.050 in.) |
| End play | - | 0.06-0.16 mm (0.002-0.006 in.) | 0.25 mm (0.010 in.) | |
| Thickness | - | 27.92-27.97 mm (1.099-1.101 in.) | 27.87 mm (1.097 in.) | |
| Countershaft 1st gear distance collar | I.D. | - | 39.95-39.96 mm (1.5728-1.5732 in.) | 39.97 mm (1.574 in.) |
| O.D. | - | 46.989-47.000 mm (1.8499-1.8504 in.) | 46.94 mm (1.848 in.) | |
| Length | - | 23.03-23.08 mm (0.907-0.909 in.) | - | |
| Countershaft 2nd gear distance collar | I.D. | - | 39.95-39.96 mm (1.5728-1.5732 in.) | 39.97 mm (1.574 in.) |
| O.D. | - | 46.989-47.000 mm (1.8499-1.8504 in.) | 46.94 mm (1.848 in.) | |
| Length | - | 28.03-28.08 mm (1.104-1.106 in.) | - | |
| Reverse idler gear | I.D. | - | 20.016-20.043 mm (0.7880-0.7891 in.) | 20.90 mm (0.832 in.) |
| Gear-to-reverse gear shaft clearance | - | 0.036-0.084 mm (0.0014-0.0033 in.) | 0.16 mm (0.006 in.) | |
| Synchro ring | Ring-to-gear clearance | Ring pushed against gear | 0.70-1.49 mm (0.028-0.059 in.) | 0.4 mm (0.016 in.) |
| Double cone synchro | Outer synchro ring-to-synchro cone clearance | Ring pushed against gear | 0.70-1.19 mm (0.028-0.047 in.) | 0.3 mm (0.012 in.) |
| Synchro cone-to-gear clearance | Ring pushed against gear | 0.50-1.04 mm (0.020-0.041 in.) | 0.3 mm (0.012 in.) | |
| Outer synchro ring-to-gear cone clearance | Ring pushed against gear | 0.95-1.68 mm (0.037-0.066 in.) | 0.6 mm (0.024 in.) | |
| Triple cone synchro | Outer synchro ring-to-synchro clearance | Ring pushed against gear | 0.70-1.19 mm (0.028-0.047 in.) | 0.3 mm (0.012 in.) |
| Synchro cone-to-gear clearance | Ring pushed against gear | 0.50-1.04 mm (0.020-0.041 in.) | 0.3 mm (0.012 in.) | |
| Outer synchro ring-to-gear clearance | Ring pushed against gear | 0.95-1.68 mm (0.037-0.066 in.) | 0.6 mm (0.024 in.) | |
| Shift fork | Fork thickness | - | 7.4-7.6 mm (0.29-0.30 in.) | - |
| Fork-to-synchro sleeve clearance | - | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.039 in.) | |
| Reverse shift fork | Finger width | - | 13.4-13.7 mm (0.527-0.539 in.) | - |
| Fork-to-reverse idler gear clearance | - | 0.20-0.59 mm (0.007-0.024 in.) | 1.2 mm (0.047 in.) | |
| Detent ball spring | Free length | 1st/2nd, 3rd/4th, 5th | 22.1 mm (0.870 in) | When worn or damaged |
| Steel ball | Ball size | - | 7.94 mm (0.3126 in) | When worn or damaged |
| Shift arm | I.D. | - | 13.973-14.000 mm (0.5501-0.5512 in.) | - |
| Shift arm thickness at contact area | - | 16.9-17.0 mm (0.665-0.669 in.) | - | |
| Shift arm-to-shift fork clearance | - | 0.2-0.5 mm (0.008-0.020 in.) | 0.6 mm (0.023 in.) | |
| Select lever | Finger width | - | 14.85-14.95 mm (0.585-0.589 in.) | - |
| Change lever | Change-to-select lever clearance | - | 0.05-0.25 mm (0.002-0.010 in.) | 0.5 mm (0.020 in.) |
| Groove width (to select lever) | - | 15.00-15.10 mm (0.591-0.594 in.) | - | |
| Shaft-to-shift arm clearance | - | 0.013-0.07 mm (0.0005-0.003 in.) | 0.1 mm (0.004 in.) | |
| M/T differential carrier | Pinion shaft contact area I.D. | - | 18.010-18.028 mm (0.7091-0.7098 in.) | - |
| Carrier-to-pinion shaft clearance | - | 0.027-0.057 mm (0.0011-0.0022 in.) | 0.1 mm (0.004 in.) | |
| Driveshaft contact area I.D. | - | 28.025-28.045 mm (1.1033-1.1041 in.) | - | |
| M/T differential pinion gear | Backlash | - | 0.05-0.15 mm (0.002-0.006 in.) | - |
| I.D. | - | 18.042-18.066 mm (0.7103-0.7113 in.) | - | |
| Pinion gear-to-pinion shaft clearance | - | 0.059-0.095 mm (0.0023-0.0037 in.) | 0.15 mm (0.006 in.) | |
| 80 mm shim | 80 mm shim-to-bearing outer race clearance in transmission housing | - | 0-0.10 mm (0-0.0039 in.) | Adjust |
| Transfer assembly | Diameter of tapered roller bearing contact area (transfer shaft) | - | 24.975-24.990 mm (0.9833-0.9838 in.) | 24.92 mm (0.9811 in.) |
| Diameter of tapered roller bearing contact area (transfer drive gear) | - | 40.002-40.018 mm (1.5749-1.5755 in.) | 38.95 mm (1.5335 in.) | |
| Diameter of tapered roller bearing contact area (driven gear side) | - | 35.002-35.018 mm (1.3780-1.3786 in.) | 34.95 mm (1.3760 in.) | |
| Diameter of tapered roller bearing contact area (splined side) | - | 26.975-26.988 mm (1.0620-1.0625 in.) | 26.92 mm (1.0598 in.) | |
| Transfer gear backlash | - | 0.06-0.16 mm (0.0024-0.0063 in.) | Adjust | |
| Total starting torque | - | 2.16-3.57 N.m (22.0-36.4 kgf.cm, 19.1-31.6 lbf.in.) | Adjust | |