R151 MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

MANUAL TRANSMISSION OIL
2.6 liters (2.7 US qts, 2.3 Imp. qts)

  • Above -10°C (14°F):

    SAE 75W-90, 80W or 80W-90

  • Below -10°C (14°F):

    SAE 75W-90
MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL
Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)
TRANSMISSION CASE OIL SEAL
Standard drive in depth 11.2 to 12.2 mm (0.441 to 0.480 in.)
BACK-UP LIGHT SWITCH
Switch Condition Specified Condition
Pushed Below 1 Ω
Released 10 kΩ or higher
MANUAL TRANSMISSION UNIT
Countershaft 5th gear inside diameter Standard 38.015 to 38.040 mm (1.4967 to 1.4976 in.)
Maximum 38.040 mm (1.4976 in.)
Countershaft 5th gear thrust clearance Standard 0.10 to 0.35 mm (0.00394 to 0.0137 in.)
Countershaft 5th gear radial clearance Standard 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
Clearance of No. 2 synchronizer ring with input shaft Standard 0.70 to 1.70 mm (0.0276 to 0.0669 in.)
Clearance of No. 3 synchronizer ring with No. 5 gear Standard 0.68 to 1.32 mm (0.0268 to 0.0519 in.)
No. 1 gear shift fork groove Standard 5.20 to 5.36 mm (0.205 to 0.211 in.)
Maximum 5.36 mm (0.211 in.)
No. 1 gear shift fork thickness Standard 4.35 to 4.65 mm (0.172 to 0.183 in.)
Minimum 4.35 mm (0.172 in.)
No. 2 gear shift fork thickness Standard 9.9 to 10.0 mm (0.390 to 0.393 in.)
Minimum 9.9 mm (0.390 in.)
No. 3 gear shift fork thickness Standard 9.76 to 10.24 mm (0.385 to 0.403 in.)
Minimum 9.76 mm (0.385 in.)
No. 3 transmission hub sleeve groove Standard 10.5 to 10.6 mm (0.414 to 0.417 in.)
Maximum 10.60 mm (0.417 in.)
Reverse idler gear inside diameter Standard 24.040 to 24.061 mm (0.9465 to 0.9472 in.)
Maximum 24.061 mm (0.9472 in.)
Reverse idler gear shaft outside diameter Standard 23.979 to 24.000 mm (0.9441 to 0.9448 in.)
Maximum 23.979 mm (0.9441 in.)
Clearance of reverse idler gear and reverse shift arm Standard 0.05 to 0.35 mm (0.00197to 0.0137 in.)
Manual transmission case ring pin specified condition Specified condition 5.5 to 7.5 mm (0.217 to 0.295 in.)
Manual transmission case straight pin specified condition Specified condition 9.0 to 11.0 mm (0.355 to 0.433 in.)
Counter shaft rear snap ring clearance Standard 0.10 mm (0.00393 in.) or less
Counter shaft rear snap ring thickness Standard 2.80 to 2.85 mm (0.111 to 0.112 in.)
2.85 to 2.90 mm (0.113 to 0.114 in.)
2.90 to 2.95 mm (0.115 to 0.116 in.)
2.95 to 3.00 mm (0.117 to 0.118 in.)
3.00 to 3.05 mm (0.119 to 0.120 in.)
3.05 to 3.10 mm (0.121 to 0.122 in.)
3.10 to 3.15 mm (0.123 to 0.124 in.)
Output shaft bearing snap ring clearance Standard 0.10 mm (0.00393 in.) or less
Output shaft bearing snap ring thickness Standard 2.65 to 2.70 mm (0.105 to 0.106 in.)
2.70 to 2.75 mm (0.107 to 0.108 in.)
2.75 to 2.80 mm (0.109 to 0.110 in.)
2.80 to 2.85 mm (0.111 to 0.112 in.)
2.85 to 2.90 mm (0.113 to 0.114 in.)
2.90 to 2.95 mm (0.115 to 0.116 in.)
2.95 to 3.00 mm (0.117 to 0.118 in.)
3.00 to 3.05 mm (0.119 to 0.120 in.)
3.05 to 3.10 mm (0.121 to 0.122 in.)
3.10 to 3.15 mm (0.122 to 0.124 in.)
3.15 to 3.20 mm (0.124 to 0.126 in.)
3.20 to 3.25 mm (0.126 to 0.128 in.)
3.25 to 3.30 mm (0.128 to 0.129 in.)
3.30 to 3.35 mm (0.130 to 0.131 in.)
3.35 to 3.40 mm (0.132 to 0.133 in.)
3.40 to 3.45 mm (0.134 to 0.135 in.)
3.45 to 3.50 mm (0.136 to 0.137 in.)
Manual transmission extension housing oil seal depth Standard -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
INPUT SHAFT
Front bearing shaft snap ring clearance Standard 0.10 mm (0.00393 in.) or less
Front bearing shaft snap ring thickness Standard 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2.15 to 2.20 mm (0.0847 to 0.0866 in.)
2.20 to 2.25 mm (0.0867 to 0.0885 in.)
2.25 to 2.30 mm (0.0886 to 0.0905 in.)
2.30 to 2.35 mm (0.0906 to 0.0925 in.)
2.35 to 2.40 mm (0.0925 to 0.0944 in.)
2.40 to 2.45 mm (0.0945 to 0.0964 in.)
OUTPUT SHAFT
1st gear thrust clearance Standard 0.30 to 0.55 mm (0.0119 to 0.0216 in.)
2nd gear thrust clearance Standard 0.10 to 0.25 mm (0.00394 to 0.00984 in.)
3rd gear thrust clearance Standard 0.10 to 0.25 mm (0.00394 to 0.00984 in.)
1st gear radial clearance Standard 0.020 to 0.073 mm (0.000788 to 0.00287 in.)
2nd gear radial clearance Standard 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
3rd gear radial clearance Standard 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
Output shaft runout Maximum 0.03 mm (0.00118 in.)
Output shaft standard outside diameter Journal A 38.979 to 38.995 mm (1.5347 to 1.5352 in.)
Journal B 46.984 to 47.000 mm (1.8498 to 1.8503 in.)
Journal C 37.984 to 38.000 mm (1.4955 to 1.4960 in.)
Output shaft flange thickness 4.8 to 5.2 mm (0.189 to 0.204 in.)
3rd gear inside diameter Standard 44.015 to 44.040 mm (1.7329 to 1.7338 in.)
Maximum 44.040 mm (1.7338 in.)
2nd gear inside diameter Standard 53.015 to 53.040 mm (2.0873 to 2.0881 in.)
Maximum 53.040 mm (2.0881 in.)
1st gear inside diameter Standard 46.015 to 46.040 mm (1.8117 to 1.8125 in.)
Maximum 46.040 mm (1.8125 in.)
1st gear thrust washer thickness Standard 5.95 to 6.05 mm (0.235 to 0.238 in.)
Maximum 5.95 mm (0.235 in.)
Clearance of No. 1 synchronizer ring with 1st gear Standard 0.65 to 1.75 mm (0.0256 to 0.0688 in.)
Clearance of No. 1 synchronizer ring with 2nd gear Standard 0.65 to 1.75 mm (0.0256 to 0.0688 in.)
Clearance of No. 2 synchronizer ring with 3rd gear Standard 0.65 to 1.75 mm (0.0256 to 0.0689 in.)
Reverse gear thickness Standard 4.95 to 5.05 mm (0.195 to 0.198 in.)
No. 2 transmission hub sleeve groove Standard 10.15 to 10.25 mm (0.400 to 0.403 in.)
Clutch hub set shaft snap ring clearance Standard 0.10 mm (0.00393 in.) or less
Clutch hub set shaft snap ring thickness Standard 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
1.85 to 1.90 mm (0.0729 to 0.0748 in.)
1.90 to 1.95 mm (0.0748 to 0.0767 in.)
1.95 to 2.00 mm (0.0768 to 0.0787 in.)
2.00 to 2.05 mm (0.0788 to 0.0807 in.)
2.05 to 2.10 mm (0.0808 to 0.0826 in.)
2.10 to 2.15 mm (0.0827 to 0.0846 in.)
Bearing shaft snap ring clearance Standard 0.10 mm (0.00393 in.) or less
Bearing shaft snap ring thickness Standard 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
2.35 to 2.40 mm (0.0926 to 0.0944 in.)
2.40 to 2.45 mm (0.0945 to 0.0964 in.)
2.45 to 2.50 mm (0.0965 to 0.0984 in.)
2.50 to 2.55 mm (0.0985 to 0.100 in.)
2.55 to 2.60 mm (0.101 to 0.102 in.)
2.60 to 2.65 mm (0.103 to 0.104 in.)
Counter Gear
Counter gear outside diameter Journal A Standard 29.984 to 30.000 mm (1.1805 to 1.1811 in.)
Minimum 29.984 mm (1.1805 in.)
Counter gear front bearing snap ring clearance Standard 0.1 mm (0.00393 in.) or less
Counter gear front bearing snap ring thickness Standard 2.05 to 2.10 mm (0.0808 to 0.0826 in.)
2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2.15 to 2.20 mm (0.0847 to 0.0866 in.)
2.20 to 2.25 mm (0.0867 to 0.0885 in.)
2.25 to 2.30 mm (0.0886 to 0.0905 in.)
2.30 to 2.35 mm (0.0906 to 0.0925 in.)