| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Transmission oil | Capacity | For fluid change: 1.5 [liter] (1.6 US qt, 1.3 lmp qt) | ||
| For overhaul: 1.6 [liter] (1.7 US qt, 1.4 lmp qt) | ||||
| Mainshaft | End play | 0.11-0.18 mm (0.004-0.007 in.) | Adjust | |
| Diameter of ball bearing contact area (clutch housing side) | 25.977-25.990 mm (1.0227-1.0232 in.) | 25.92 mm (1.021 in.) | ||
| Diameter of distance collar contact area | 28.992-29.005 mm (1.1414-1.1419 in.) | 28.93 mm (1.139 in.) | ||
| Diameter of needle bearing contact area | 34.984-35.000 mm (1.3773-1.3780 in.) | 34.93 mm (1.375 in.) | ||
| Diameter of ball bearing contact area (transmission housing side) | 25.987-26.000 mm (1.0231-1.0236 in.) | 25.93 mm (1.021 in.) | ||
| Diameter of pilot bearing contact area | 14.870-14.890 mm (0.5854-0.5862 in.) | ——— | ||
| Runout | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | ||
| Mainshaft 3rd and 4th gears | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | 39.07 mm (1.538 in.) | |
| End play | 3rd gear | 0.06-0.21 mm (0.002-0.008 in.) | 0.33 mm (0.013 in.) | |
| 4rd gear | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.012 in.) | ||
| Thickness | 3rd gear | 27.92-27.97 mm (1.099-1.101 in.) | 27.85 mm (1.096 in.) | |
| 4th gear | 27.02-27.07 mm (1.064-1.066 in.) | 26.95 mm (1.061 in.) | ||
| Mainshaft 5th gear | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | 39.07 mm (1.538 in.) | |
| End play | 0.06-0.19 mm (0.002-0.007 in.) | 0.31 mm (0.012 in.) | ||
| Thickness | 28.92-28.97 mm (1.139-1.141 in.) | 28.85 mm (1.136 in.) | ||
| Countershaft | Diameter of needle bearing contact area (clutch housing side) | 34.000-34.015 mm (1.3386-1.3392 in.) | 33.95 mm (1.337 in.) | |
| Diameter of ball bearing contact area (transmission housing side) | 24.980-24.993 mm (0.9835-0.9840 in.) | 24.93 mm (0.981 in.) | ||
| Diameter of 1st gear contact area | 37.984-38.000 mm (1.4954-1.4961 in.) | 37.934 mm (1.493 in.) | ||
| Runout | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | ||
| Countershaft 1st gear | I.D. | 43.009-43.025 mm (1.6933-1.6939 in.) | 43.070 mm (1.6957 in.) | |
| End play | 0.03-0.12 mm (0.001-0.005 in.) | 0.24 mm (0.009 in.) | ||
| Thickness | 26.89-26.94 mm (1.059-1.061 in.) | 26.86 mm (1.057 in.) | ||
| Countershaft 2nd gear | I.D. | 45.009-45.025 mm (1.7720-1.7726 in.) | 45.07 mm (1.774 in.) | |
| End play | 0.04-0.12 mm (0.002-0.005 in.) | 0.24 mm (0.009 in.) | ||
| Thickness | 27.41-27.46 mm (1.079-1.081 in.) | 27.36 mm (1.077 in.) | ||
| Countershaft 2nd gear distance collar | I.D. | 34.000-34.010 mm (1.3386-1.3390 in.) | 34.04 mm (1.340 in.) | |
| O.D. | 39.989-40.000 mm (1.5744-1.5748 in.) | 39.93 mm (1.572 in.) | ||
| Length | 27.53-27.56 mm (1.084-1.085 in.) | 27.51 mm (1.083 in.) |
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Mainshaft 4th and 5th gears distance collar | I.D. | 29.014-29.024 mm (1.1423-1.1427 in.) | 29.06 mm (1.144 in.) | |
| O.D. | 34.989-35.000 mm (1.3775-1.3780 in.) | 34.93 mm (1.375 in.) | ||
| Length
| A | 51.97-52.03 mm (2.046-2.048 in.) | ——— | |
| B | 24.03-24.06 mm (0.946-0.947 in.) | ——— | ||
| Mainshaft MBS distance collar | I.D. | 26.02-26.17 mm (1.024-1.030 in.) | ||
| Length | 12.00-12.05 mm (0.472-0.474 in.) | ——— | ||
| Reverse idler gear | I.D. | 15.016-15.043 mm (0.5912-0.5922 in.) | 15.08 mm (0.594 in.) | |
| Gear-to-reverse gear shaft clearance | 0.032-0.077 mm (0.0012-0.0030 in.) | 0.14 mm (0.006 in.) | ||
| Synchro ring | Ring-to-gear clearance | Ring pushed against gear | 0.85-1.10 mm (0.033-0.043 in.) | 0.4 mm (0.02 in.) |
| Shift fork | Finger thickness | 1st-2nd and 3rd-4th forks | 7.4-7.6 mm (0.29-0.30 in.) | ——— |
| 5th forks | 6.7-6.9 mm (0.26-0.27 in.) | ——— | ||
| Fork-to-synchro sleeve clearance | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.04 in.) | ||
| Reverse shift fork | Pawl groove width | 13.5-13.8 mm (0.53-0.54 in.) | ——— | |
| Fork-to-reverse idler gear clearance | 1.3-1.9 mm (0.05-0.07 in.) | 2.5 mm (0.1 in.) | ||
| Shift arm | I.D. | 13.973-14.000 mm (0.5501-0.5512 in.) | ——— | |
| Shift fork diameter at contact area | 12.9-13.0 mm (0.508-0.512 in.) | ——— | ||
| Shift arm-to-shaft lever clearance | 0.2-0.5 mm (0.008-0.020 in.) | 0.62 mm (0.024 in.) | ||
| Select lever | Finger width | 12.80-12.95 mm (0.504-0.510 in.) | ——— | |
| Shift lever | Shaft-to-select lever clearance | 0.05-0.35 mm (0.002-0.014 in.) | 0.55 mm (0.024 in.) | |
| Groove (to select lever) | 13.00-13.15 mm (0.512-0.518 in.) | ——— | ||
| Shaft-to-shift arm clearance | 0.013-0.070 mm (0.0005-0.0028 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 | 0.023-0.057 mm (0.0009-0.0022 in.) | 0.1 mm (0.004 in.) | ||
| Driveshaft contact area I.D. | 26.025-26.045 mm (1.0246-1.0254 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 | 0.055-0.095 mm (0.0022-0.0037 in.) | 0.15 mm (0.006 in.) | ||
| 72 mm shim | 72 mm shim-to-bearing outer race clearance in transmission housing | 0-0.1 mm (0-0.004 in.) | Adjust |