| Reverse idler gear shaft outer diameter | Standard Minimum |
15.97 to 15.98 mm (0.6287 to 0.6292 in.) 15.97 mm (0.6286 in.) |
| Reverse idler gear inside diameter | Standard Maximum |
16.04 to 16.05 mm (0.6315 to 0.6322 in.) 16.05 mm (0.6322 in.) |
| Reverse shift fork inside diameter | Standard Standard Maximum Maximum |
14.27 to 14.42 mm (0.5618 to 0.5677 in.) for A 14.01 to 14.03 mm (0.5516 to 0.5527 in.) for B 14.42 mm (0.5677 in.) for A 14.03 mm (0.5527 in.) for B |
| No. 1 shift fork shaft outer diameter | Standard Minimum |
13.97 to 13.98 mm (0.5499 to 0.5505 in.) 13.97 mm (0.5499 in.) |
| No. 2 shift fork shaft outer diameter | Standard Minimum |
13.97 to 13.98 mm (0.5499 to 0.5505 in.) 13.97 mm (0.5499 in.) |
| No. 3 shift fork shaft outer diameter | Standard Minimum |
13.97 to 13.98 mm (0.5499 to 0.5505 in.) 13.97 mm (0.5499 in.) |
| No. 1 gear shift fork inside diameter and thickness | Standard | 9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A 9.9 to 10.0 mm (0.3898 to 0.3937 in.) for B 14.00 to 14.02 mm (0.5510 to 0.5522 in.) for C |
| No. 2 gear shift fork inside diameter and thickness | Standard | 9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A 14.00 to 14.02 mm (0.5510 to 0.5522 in.) for B |
| No. 3 gear shift fork inside diameter and thickness | Standard | 9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A 14.00 to 14.02 mm (0.5510 to 0.5522 in.) for B |
| No. 1 gear shift head | Standard Maximum |
14.00 to 14.05 mm (0.5510 to 0.5533 in.) 14.05 mm (0.5533 in.) |
| No. 3 gear shift head | Standard Standard Maximum Maximum |
14.00 to 14.05 mm (0.5510 to 0.5533 in.) for A 14.2 to 14.4 mm (0.5591 to 0.5669 in.) for B 14.05 mm (0.5533 in.) for A 14.4 mm (0.5669 in.) for B |
| Input shaft runout | Maximum | 0.03 mm (0.0012 in.) |
| Input shaft journal diameter | Standard | 25.502 to 25.515 mm (1.0040 to 1.0045 in.) for A 30.985 to 31.000 mm (1.2199 to 1.2205 in.) for B 33.985 to 34.000 mm (1.3380 to 1.3386 in.) for C,D 23.002 to 23.015 mm (0.9056 to 0.9056 in.) for E 22.967 to 23.000 mm (0.9042 to 0.9055 in.) for F |
| 3rd gear inside diameter | Standard Maximum |
39.015 to 39.031 mm (1.5360 to 1.5367 in.) 39.031 mm (1.5367 in.) |
| 4th gear inside diameter | Standard Maximum |
39.015 to 39.031 mm (1.5360 to 1.5367 in.) 39.031 mm (1.5367 in.) |
| 5th gear inside diameter | Standard Maximum |
36.015 to 36.031 mm (1.4180 to 1.4185 in.) 36.031 mm (1.4185 in.) |
| 3rd gear synchronizer ring to 3rd gear clearance | Standard Minimum |
0.75 to 1.65 mm (0.030 to 0.064 in.) 0.75 mm (0.030 in.) |
| 4th gear synchronizer ring to 4th gear clearance | Standard Minimum |
0.75 to 1.65 mm (0.030 to 0.064 in.) 0.75 mm (0.030 in.) |
| 5th gear synchronizer ring to 5th gear clearance | Standard Minimum |
0.80 to 1.60 mm (0.031 to 0.063 in.) 0.80 mm (0.031 in.) |
| Transmission hub sleeve No.2 to shift fork No.2 clearance | Standard | 0.15 to 0.35 mm (0.0059 to 0.0138 in.) (A-B) |
| Transmission hub sleeve No.3 to shift fork No.3 clearance | Standard | 0.15 to 0.35 mm (0.0059 to 0.0138 in.) (A-B) |
| Output shaft runout | Maximum | 0.03 mm (0.0012 in.) |
| Output shaft journal diameter | Standard | 23.002 to 23.015 mm (0.9056 to 0.9061 in.) for A 28.3 mm to (1.1142 in.) for B, C 33.985 to 34.000 mm (1.3380 to 1.3386 in.) for D,E 25.002 to 25.015 mm (0.9843 to 0.9848 in.) for F |
| 1st gear diameter | Standard Maximum |
39.015 to 39.031 mm (1.5360 to 1.5367 in.) 39.031 mm (1.5367 in.) |
| Transaxle case straight pin depth | - | 10.5 to 11.5 mm (0.4134 to 0.4528 in.) |
| 2nd gear diameter | Standard Maximum |
39.015 to 39.031 mm (1.5360 to 1.5367 in.) 39.031 mm (1.5367 in.) |
| 1st gear synchronizer ring to 1st gear clearance | Standard Minimum |
0.80 to 1.60 mm (0.031 to 0.063 in.) 0.80 mm (0.031 in.) |
| 2nd gear synchronizer ring to 2nd gear clearance | Standard Minimum |
0.80 to 1.60 mm (0.031 to 0.063 in.) 0.80 mm (0.031 in.) |
| Reverse gear to reverse gear fork clearance | Standard | 0.15 to 0.35 mm (0.0059 to 0.0138 in.) (A-B) |
| Differential case side gear backlash | Standard | 0.05 mm to 0.20 mm (0.0020 to 0.0079 in.) |
| Differential case side gear thrust washer thickness | - | 0.50 mm (0.0197 in.) 0.55 mm (0.0217 in.) 0.60 mm (0.0236 in.) 0.65 mm (0.0256 in.) 0.70 mm (0.0276 in.) 0.75 mm (0.0295 in.) 0.80 mm (0.0315 in.) 0.85 mm (0.0335 in.) 0.90 mm (0.0354 in.) 0.95 mm (0.0374 in.) |
| Clutch hub No.1 shaft snap ring clearance | Standard | 0 to 0.1 mm (0 to 0.0039 in.) |
| Clutch hub No.1 shaft snap ring thickness | Mark A Mark B Mark C Mark D Mark E Mark F |
2.28 mm (0.0898 in.) 2.34 mm (0.0921 in.) 2.40 mm (0.0945 in.) 2.46 mm (0.0969 in.) 2.52 mm (0.0992 in.) 2.58 mm (0.1016 in.) |
| 1st gear thrust clearance | Standard Maximum |
0.10 to 0.45 mm (0.0039 to 0.0177 in.) 0.45 mm (0.0177 in.) |
| 1st gear radial clearance | Standard Maximum |
0.015 to 0.056 mm (0.0006 to 0.0022 in.) 0.056 mm (0.0022 in.) |
| 2nd gear thrust clearance | Standard Maximum |
0.10 to 0.55 mm (0.0039 to 0.0217 in.) 0.55 mm (0.0217 in.) |
| 2nd gear radial clearance | Standard Maximum |
0.015 to 0.056 mm (0.0006 to 0.0022 in.) 0.056 mm (0.0022 in.) |
| Counter 5th gear shaft snap ring clearance | Standard | 0.1 mm (0.0039 in.) or less |
| Counter 5th gear shaft snap ring thickness | Mark A Mark B Mark C Mark D Mark E Mark F Mark G Mark H Mark J |
2.22 mm (0.0874 in.) 2.28 mm (0.0898 in.) 2.34 mm (0.0921 in.) 2.40 mm (0.0945 in.) 2.46 mm (0.0969 in.) 2.52 mm (0.0992 in.) 2.58 mm (0.1016 in.) 2.64 mm (0.1039 in.) 2.70 mm (0.1063 in.) |
| Clutch hub No.2 setting shaft snap ring clearance | Standard | 0.1 mm (0.0039 in.) or less |
| Clutch hub No.2 setting shaft snap ring thickness | Mark A Mark B Mark C Mark D Mark E Mark F |
2.28 mm (0.0898 in.) 2.34 mm (0.0921 in.) 2.40 mm (0.0945 in.) 2.46 mm (0.0969 in.) 2.52 mm (0.0992 in.) 2.58 mm (0.1016 in.) |
| 3rd gear thrust clearance | Standard Maximum |
0.10 to 0.35 mm (0.0039 to 0.0138 in.) 0.35 mm (0.0138 in.) |
| 3rd gear radial clearance | Standard Maximum |
0.015 to 0.058 mm (0.0006 to 0.0023 in.) 0.058 mm (0.0023 in.) |
| 5th gear shaft snap ring clearance | Standard | 0.1 mm (0.0039 in.) or less |
| 5th gear shaft snap ring thickness | Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 |
2.28 mm (0.0898 in.) 2.34 mm (0.0921 in.) 2.40 mm (0.0945 in.) 2.46 mm (0.0969 in.) 2.52 mm (0.0992 in.) 2.58 mm (0.1016 in.) |
| 4th gear thrust clearance | Standard Maximum |
0.1 to 0.55 mm (0.0039 to 0.0217 in.) 0.55 mm (0.0217 in.) |
| 4th gear radial clearance | Standard Maximum |
0.015 to 0.058 mm (0.0006 to 0.0023 in.) 0.058 mm (0.023 in.) |
| 5th gear thrust clearance | Standard Maximum |
0.10 to 0.50 mm (0.0039 to 0.0197 in.) 0.50 mm (0.0197 in.) |
| 5th gear radial clearance | Standard Maximum |
0.015 to 0.058 mm (0.0006 to 0.0023 in.) 0.058 mm (0.0023 in.) |
| Differential side bearing preload | New bearing | 0.78 to 1.57 N*m (7.96 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf) |
| Used bearing | 0.49 to 0.98 N*m (5.00 to 10.00 kgf*cm, 4.30 to 8.67 in.*lbf) | |
| Differential case shim thickness (for TMMP Made) |
Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17 Mark 18 Mark 19 |
1.100 mm (0.0433 in) 1.150 mm (0.0453 in) 1.200 mm (0.0472 in) 1.250 mm (0.0492 in) 1.300 mm (0.0512 in) 1.350 mm (0.0532 in) 1.400 mm (0.0551 in) 1.450 mm (0.0571 in) 1.500 mm (0.0590 in) 1.550 mm (0.0610 in) 1.600 mm (0.0630 in) 1.650 mm (0.0650 in) 1.700 mm (0.0669 in) 1.750 mm (0.0689 in) 1.800 mm (0.0709 in) 1.850 mm (0.0728 in) 1.900 mm (0.0748 in) 1.950 mm (0.0768 in) 2.000 mm (0.0787 in) |
| Differential case shim thickness (for AISIN AI Made) |
Mark AA Mark BB Mark CC Mark DD Mark EE Mark FF Mark GG Mark HH Mark JJ Mark KK Mark LL Mark MM Mark NN Mark PP Mark QQ Mark RR Mark SS Mark TT Mark UU |
2.100 mm (0.0827 in.) 2.150 mm (0.0847 in.) 2.200 mm (0.0866 in.) 2.250 mm (0.0886 in.) 2.300 mm (0.0906 in.) 2.350 mm (0.0925 in.) 2.400 mm (0.0945 in.) 2.450 mm (0.0965 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) |
| Output shaft bearing preload | New bearing | 3.37 to 6.73 N*m (34.36 to 68.62 kgf*cm, 29.83 to 59.56 in.*lbf) |
| Used bearing | 2.10 to 4.20 N*m (21.42 to 42.83 kgf*cm, 18.59 to 37.17 in.*lbf) | |
| Rear output shaft bearing shim thickness | Mark A Mark B Mark C Mark D Mark E Mark F Mark G Mark H Mark J Mark K Mark L Mark M Mark N Mark P Mark Q |
1.550 mm (0.0610 in.) 1.600 mm (0.0630 in.) 1.650 mm (0.0650 in.) 1.700 mm (0.0669 in.) 1.750 mm (0.0689 in.) 1.800 mm (0.0709 in.) 1.850 mm (0.0728 in.) 1.900 mm (0.0748 in.) 1.950 mm (0.0768 in.) 2.000 mm (0.0787 in.) 2.050 mm (0.0807 in.) 2.100 mm (0.0827 in.) 2.150 mm (0.0846 in.) 2.200 mm (0.0866 in.) 2.250 mm (0.0886 in.) |
| Rear input shaft bearing to manual transmission case clearance | Standard | 0.1 mm (0.00394 in.) or less |
| Rear input shaft bearing shim thickness | Mark F Mark G Mark H Mark J Mark K Mark L Mark M Mark N Mark P Mark Q Mark R Mark S Mark T |
1.800 mm (0.0709 in.) 1.850 mm (0.0728 in.) 1.900 mm (0.0748 in.) 1.950 mm (0.0768 in.) 2.000 mm (0.0787 in.) 2.050 mm (0.0807 in.) 2.100 mm (0.0827 in.) 2.150 mm (0.0846 in.) 2.200 mm (0.0866 in.) 2.250 mm (0.0886 in.) 2.300 mm (0.0906 in.) 2.350 mm (0.0925 in.) 2.400 mm (0.0945 in.) |
| Manual transmission case oil seal drive in depth | - | 2.1 to 3.1 mm (0.083 to 0.122 in.) |
| Manual transaxle case oil seal drive in depth | - | 1.7 to 2.7 mm (0.067 to 0.106 in.) |
| Front transaxle case oil seal drive in depth | - | 14.4 to 15.4 mm (0.567 to 0.606 in.) |
| Control shaft cover oil seal drive in depth | - | 0 to 0.5 mm (0 to 0.0196 in.) |
| Select lever shaft oil seal drive in depth | - | 2.0 to 2.5 mm (0.0788 to 0.0984 in.) |
| Shift lever inner No. 1 set slotted spring pin drive in depth | - | -0.5 to 0.5 mm (-0.0196 to 0.0196 in.) |