RC60 / RC61 MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

MANUAL TRANSMISSION OIL
2.7 liters (2.9 US qts, 2.4 Imp. qts) SAE 75W-90
MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL
Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
SPEED SENSOR
Tester Connection Condition Specified Condition
1 (NMO) - 2 (NMB) Low signal 4 to 8 mA
1 (NMO) - 2 (NMB) High signal 12 to 16 mA
BACK-UP LIGHT SWITCH
Switch Condition Specified Condition
Pushed Below 1 Ω
Released 10 kΩ or higher
MANUAL TRANSMISSION UNIT
Reverse idler gear radial clearance Standard 0.015 to 0.050 mm (0.000591 to 0.00196 in.)
Maximum 0.050 mm (0.00196 in.)
Clearance of No. 4 synchronizer ring with output shaft Standard 0.82 to 1.48 mm (0.0323 to 0.0582 in.)
Minimum 0.82 mm (0.0323 in.)
Reverse idler gear thrust clearance Standard 0.196 to 0.939 mm (0.0078 to 0.0369 in.)
Maximum 0.939 mm (0.0369 in.)
Rear transmission case straight pin protrusion height Specified condition 5.5 to 6.5 mm (0.2166 to 0.2559 in.)
Extension housing ring pin protrusion height Specified condition 3.5 to 4.5 mm (0.1378 to 0.1771 in.)
Transmission intermediate plate ring pin protrusion height Specified condition 5.5 to 7.5 mm (0.2166 to 0.2952 in.)
Front transmission case straight pin protrusion height Specified condition 9.5 to 10.5 mm (0.3741 to 0.4133 in.)
No. 1 gear shift fork shaft depth Standard 0 to 0.5 mm (0 to 0.0196 in.)
No. 4 gear shift fork shaft depth Standard 0 to 0.5 mm (0 to 0.0196 in.)
No. 2 gear shift fork shaft depth Standard 0 to 0.5 mm (0 to 0.0196 in.)
Shift and select lever shaft needle roller bearing dimension Dimension 0.5 to 1.5 mm (0.0197 to 0.0591 in.)
Shift and select lever depth Standard 0 to 0.5 mm (0 to 0.0196 in.)
Shift fork shaft bearing dimension Dimension 147.7 to 148.7 mm (5.815 to 5.854 in.)
Shift and select lever shaft needle roller bearing (front side) dimension Dimension 0.5 to 1.5 mm (0.0197 to 0.0590 in.)
Shift fork shaft bearing dimension Dimension 106.9 to 107.9 mm (4.209 to 4.248 in.)
Shift and select lever shaft needle roller bearing (rear side) dimension Dimension 2.5 to 3.5 mm (0.0985 to 0.1377 in.)
Output shaft bearing shim thickness 01 Standard 2.214 to 2.230 mm (0.0872 to 0.0877 in.)
02 Standard 2.230 to 2.246 mm ( 0.0878 to 0.0884 in.)
03 Standard 2.246 to 2.262 mm ( 0.0885 to 0.0890 in.)
04 Standard 2.262 to 2.278 mm ( 0.0891 to 0.0896 in.)
05 Standard 2.278 to 2.294 mm ( 0.0897 to 0.0903 in.)
06 Standard 2.294 to 2.310 mm ( 0.0904 to 0.0909 in.)
07 Standard 2.310 to 2.326 mm ( 0.0910 to 0.0915 in.)
08 Standard 2.326 to 2.342 mm ( 0.0916 to 0.0922 in.)
09 Standard 2.342 to 2.358 mm ( 0.0923 to 0.0928 in.)
10 Standard 2.358 to 2.374 mm ( 0.0929 to 0.0934 in.)
11 Standard 2.374 to 2.390 mm ( 0.0935 to 0.0940 in.)
12 Standard 2.390 to 2.406 mm ( 0.0941 to 0.0947 in.)
13 Standard 2.406 to 2.422 mm ( 0.0948 to 0.0953 in.)
14 Standard 2.422 to 2.438 mm ( 0.0954 to 0.0959 in.)
15 Standard 2.438 to 2.454 mm ( 0.0960 to 0.0966 in.)
16 Standard 2.454 to 2.470 mm ( 0.0967 to 0.0972 in.)
17 Standard 2.470 to 2.486 mm ( 0.0973 to 0.0978 in.)
18 Standard 2.486 to 2.502 mm ( 0.0979 to 0.0985 in.)
19 Standard 2.502 to 2.518 mm ( 0.0986 to 0.0991 in.)
20 Standard 2.518 to 2.534 mm ( 0.0992 to 0.0997 in.)
21 Standard 2.534 to 2.550 mm ( 0.0998 to 0.1003 in.)
22 Standard 2.550 to 2.566 mm ( 0.1004 to 0.1010 in.)
23 Standard 2.566 to 2.582 mm ( 0.1011 to 0.1016 in.)
24 Standard 2.582 to 2.598 mm ( 0.1017 to 0.1022 in.)
25 Standard 2.598 to 2.614 mm ( 0.1023 to 0.1029 in.)
26 Standard 2.614 to 2.630 mm ( 0.1030 to 0.1035 in.)
27 Standard 2.630 to 2.646 mm ( 0.1036 to 0.1041 in.)
28 Standard 2.646 to 2.662 mm ( 0.1042 to 0.1048 in.)
29 Standard 2.662 to 2.678 mm ( 0.1049 to 0.1054 in.)
30 Standard 2.678 to 2.694 mm ( 0.1055 to 0.1060 in.)
31 Standard 2.694 to 2.710 mm ( 0.1061 to 0.1066 in.)
32 Standard 2.710 to 2.726 mm ( 0.1067 to 0.1073 in.)
33 Standard 2.726 to 2.742 mm ( 0.1074 to 0.1079 in.)
34 Standard 2.742 to 2.758 mm ( 0.1080 to 0.1085 in.)
35 Standard 2.758 to 2.774 mm ( 0.1086 to 0.1092 in.)
36 Standard 2.774 to 2.790 mm ( 0.1093 to 0.1098 in.)
37 Standard 2.790 to 2.806 mm ( 0.1099 to 0.1104 in.)
38 Standard 2.806 to 2.822 mm ( 0.1105 to 0.1111 in.)
39 Standard 2.822 to 2.838 mm ( 0.1112 to 0.1117 in.)
40 Standard 2.838 to 2.854 mm ( 0.1118 to 0.1123 in.)
41 Standard 2.854 to 2.870 mm ( 0.1124 to 0.1129 in.)
42 Standard 2.870 to 2.886 mm ( 0.1130 to 0.1136 in.)
43 Standard 2.886 to 2.902 mm ( 0.1137 to 0.1142 in.)
44 Standard 2.902 to 2.918 mm ( 0.1143 to 0.1148 in.)
45 Standard 2.918 to 2.934 mm ( 0.1149 to 0.1155 in.)
46 Standard 2.934 to 2.950 mm ( 0.1156 to 0.1161 in.)
47 Standard 2.950 to 2.966 mm ( 0.1162 to 0.1167 in.)
INPUT SHAFT
3rd gear thrust clearance Standard 0.200 to 0.490 mm (0.0079 to 0.0192 in.)
3rd gear radial clearance Standard 0.0150 to 0.065 mm (0.0006 to 0.0025 in.)
6th gear thrust clearance Standard 0.150 to 0.580 mm (0.0059 to 0.0228 in.)
6th gear radial clearance Standard 0.015 to 0.067 mm (0.0006 to 0.0026 in.)
5th gear thrust clearance Standard 0.150 to 0.410 mm (0.0060 to 0.0161 in.)
5th gear radial clearance Standard 0.013 to 0.054 mm (0.0006 to 0.0021 in.)
Input shaft runout Maximum 0.03 mm (0.0012 in.)
Input shaft standard outside diameter Journal A Standard 34.009 to 34.022 mm (1.3390 to 1.3394 in.)
Minimum 34.009 mm (1.3389 in.)
Journal B Standard 44.985 to 45.000 mm (1.7711 to 1.7716 in.)
Minimum 44.985 mm (1.7711 in.)
Journal C Standard 44.985 to 45.000 mm (1.7711 to 1.7716 in.)
Minimum 44.985 mm (1.7711 in.)
Journal D Standard 41.985 to 42.000 mm (1.6530 to 1.6535 in.)
Minimum 41.985 mm (1.6530 in.)
Journal E Standard 32.967 to 32.98 mm (1.2980 to 1.2984 in.)
Minimum 32.967 mm (1.2980 in.)
5th gear inside diameter Standard 53.013 to 53.029 mm (2.0872 to 2.0877 in.)
Maximum 53.029 mm (2.0877 in.)
6th gear inside diameter Standard 51.015 to 51.040 mm (2.0085 to 2.0094 in.)
Maximum 51.040 mm (2.0094 in.)
3rd gear inside diameter Standard 51.015 to 51.040 mm (2.0085 to 2.0094 in.)
Maximum 51.040 mm (2.0094 in.)
No. 2 transmission hub sleeve clearance No. 2 gear shift fork Standard 0.28 to 0.84 mm (0.0110 to 0.0331 in.)
No. 3 gear shift fork Standard 0.28 to 0.84 mm (0.0110 to 0.0331 in.)
Clearance of No. 3 synchronizer ring with 5th gear Standard 0.77 to 1.63 mm (0.0304 to 0.0641 in.)
Minimum 0.77 mm (0.0304 in.)
Clearance of No. 3 synchronizer ring with 6th gear Standard 0.77 to 1.63 mm (0.0304 to 0.0641 in.)
Minimum 0.77 mm (0.0304 in.)
Clearance of No. 3 synchronizer ring set with 3rd gear Standard 0.86 to 2.02 mm (0.0339 to 0.0795 in.)
Minimum 0.86 mm (0.0339 in.)
3rd gear thrust washer thickness Standard 7.62 to 7.68 mm (0.3000 to 0.3023 in.)
Minimum 7.62 mm (0.3000 in.)
Input shaft bearing snap ring clearance Standard 0.1 mm (0.00394 in.) or less
Input shaft bearing snap ring thickness A Standard 2.65 to 2.70 mm (0.1044 to 0.1062 in.)
B Standard 2.70 to 2.75 mm (0.1063 to 0.1082 in.)
C Standard 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
D Standard 2.80 to 2.85 mm (0.1103 to 0.1122 in.)
E Standard 2.85 to 2.90 mm (0.1122 to 0.1141 in.)
F Standard 2.90 to 2.95 mm (0.1142 to 0.1161 in.)
Clutch hub set shaft snap ring clearance Standard 0.10 mm (0.00394 in.) or less
Clutch hub set shaft snap ring thickness A Standard 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
B Standard 1.85 to 1.90 mm (0.0729 to 0.0748 in.)
C Standard 1.90 to 1.95 mm (0.0749 to 0.0767 in.)
D Standard 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
E Standard 2.00 to 2.05 mm (0.0788 to 0.0807 in.)
F Standard 2.05 to 2.10 mm (0.0808 to 0.0826 in.)
Gear thrust washer shaft snap ring clearance Standard 0.10 mm (0.00394 in.) or less
Gear thrust washer shaft snap ring thickness A Standard 2.07 to 2.12 mm (0.0815 to 0.0834 in.)
B Standard 2.12 to 2.17 mm (0.0835 to 0.0854 in.)
C Standard 2.17 to 2.22 mm (0.0855 to 0.0874 in.)
D Standard 2.22 to 2.27 mm (0.0875 to 0.0893 in.)
E Standard 2.27 to 2.32 mm (0.0894 to 0.0913 in.)
F Standard 2.32 to 2.37 mm (0.0914 to 0.0933 in.)
No. 2 clutch hub setting shaft snap ring clearance Standard 0.10 mm (0.00394 in.) or less
No. 2 clutch hub setting shaft snap ring thickness A Standard 2.50 to 2.55 mm (0.0983 to 0.1004 in.)
B Standard 2.55 to 2.60 mm (0.1004 to 0.1023 in.)
C Standard 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
D Standard 2.65 to 2.70 mm (0.1044 to 0.1062 in.)
E Standard 2.70 to 2.75 mm (0.1063 to 0.1082 in.)
F Standard 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
OUTPUT SHAFT
Output shaft inside diameter Standard 45.009 to 45.025 mm (1.7721 to 1.7726 in.)
Maximum 45.025 mm (1.7726 in.)
COUNTER GEAR
Countershaft reverse gear thrust clearance Standard 0.150 to 0.300 mm (0.0060 to 0.0118 in.)
Countershaft reverse gear radial clearance Standard 0.015 to 0.065 mm (0.0006 to 0.0025 in.)
Countershaft 1st speed gear thrust clearance Standard 0.150 to 0.480 mm (0.0060 to 0.0188 in.)
Countershaft 1st speed gear radial clearance Standard 0.015 to 0.067 mm (0.0006 to 0.0026 in.)
Countershaft 2nd speed gear thrust clearance Standard 0.150 to 0.480 mm (0.0060 to 0.0188 in.)
Countershaft 2nd speed gear radial clearance Standard 0.015 to 0.067 mm (0.0006 to 0.0026 in.)
Counter gear runout Maximum 0.03 mm (0.00118 in.)
Counter gear standard outside diameter Journal A Standard 35.002 to 35.015 mm (1.3781 to1.3785 in.)
Minimum 35.002 mm (1.3781 in.)
Journal B Standard 36.985 to 37.000 mm (1.4561 to1.4566 in.)
Minimum 36.985 mm (1.4561 in.)
Journal C Standard 47.985 to 48.000 mm (1.8892 to1.8897 in.)
Minimum 47.985 mm (1.8892 in.)
Journal D Standard 53.985 to 54.000 mm (2.1254 to2.1259 in.)
Minimum 53.985 mm (2.1254 in.)
Journal E Standard 34.002 to 34.015 mm (1.3387 to1.3391 in.)
Minimum 34.002 mm (1.3387 in.)
Countershaft reverse gear inside diameter Standard 51.015 to 51.040 mm (2.0085 to 2.0094 in.)
Maximum 51.040 mm (2.0094 in.)
Countershaft 1st speed gear inside diameter Standard 54.015 to 54.040 mm (2.1266 to 2.1275 in.)
Maximum 54.040 mm (2.1275 in.)
Countershaft 2nd speed gear inside diameter Standard 60.015 to 60.040 mm (2.3628 to 2.3637 in.)
Maximum 60.040 mm (2.3637 in.)
Clearance of No. 4 transmission hub sleeve with No. 4 gear shift fork Standard 0.30 to 0.50 mm (0.012 to 0.019 in.)
Clearance of No. 1 transmission hub sleeve with No. 1 gear shift fork Standard 0.15 to 0.35 mm (0.006 to 0.013 in.)
Clearance of No. 1 synchronizer ring set with countershaft 1st speed gear Standard 0.83 to 1.77 mm (0.0327 to 0.0696 in.)
Minimum 0.83 mm (0.0326 in.)
Clearance of No. 2 synchronizer ring set with countershaft 2nd speed gear Standard 0.88 to 1.72 mm (0.0347 to 0.0677 in.)
Minimum 0.88 mm (0.0347 in.)
Clearance of synchronizer ring with countershaft 2 nd speed gear Standard 0.65 to 1.35 mm (0.0256 to 0.0531 in.)
Minimum 0.65 mm (0.0256 in.)
No. 1 clutch hub shaft snap ring clearance Standard 0.10 mm (0.00394 in.) or less
No. 1 clutch hub shaft snap ring thickness A Standard 2.28 to 2.33 mm (0.0898 to 0.0917 in.)
B Standard 2.33 to 2.38 mm (0.0918 to 0.0937 in.)
C Standard 2.38 to 2.43 mm (0.0938 to 0.0956 in.)
D Standard 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
E Standard 2.48 to 2.53 mm (0.0977 to 0.0996 in.)
F Standard 2.53 to 2.58 mm (0.0997 to 0.1015 in.)
Rear counter gear bearing snap ring clearance Standard 0.10 mm (0.00394 in.) or less
Rear counter gear bearing snap ring thickness A Standard 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
B Standard 2.50 to 2.55 mm (0.0985 to 0.1003 in.)
C Standard 2.55 to 2.60 mm (0.1004 to 0.1023 in.)
D Standard 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
E Standard 2.65 to 2.70 mm (0.1044 to 0.1062 in.)
F Standard 2.70 to 2.75 mm (0.1063 to 0.1082 in.)
G Standard 2.75 to 2.80 mm (0.1083 to 0.1102 in.)