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Service Data

Manual Transaxle Specifications

Transmission case oil seal drive in depth 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
Front transaxle case cover oil seal drive in depth 0 ± 0.5 mm (0 ± 0.020 in.)
Manual transaxle assy
5th gear thrust clearance Standard clearance 0.10 - 0.65 mm (0.0039 - 0.0256 in.)
5th gear radial clearance Standard clearance 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Reverse idler gear sub-assy inside diameter Standard inside diameter 20.056 - 20.074 mm (0.7896 - 0.7903 in.)
Maximum inside diameter 20.074 mm (0.7903 in.)
Reverse idler gear shaft outer diameter Standard outer diameter 19.984 - 20.000 mm (0.7868 - 0.7874 in.)
Minimum outer diameter 19.984 mm (0.7868 in.)
Transmission hub sleeve No.3 groove - thickness of the claw part on gear shift fork No.3    
Standard clearance 0.15 - 0.35 mm (0.0059 - 0.0138 in.)
5th gear inside diameter Standard inside diameter 34.981 - 34.997 mm (1.3772 - 1.3778 in.)
Maximum inside diameter 34.997 mm (1.3778 in.)
Control shaft cover bimetal formed bush clearance 0.081 - 0.149 mm (0.0032 - 0.0059 in.)
Front transaxle case cover oil seal driven in depth 0 ± 0.5 mm (0 ± 0.020 in.)
Transmission case oil seal driven in depth 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
Output shaft rear bearing clearance 3.8 - 4.4 mm (0.150 - 0.173 in.)
Output shaft bearing preload New bearing 0.8 - 1.6 N.m (8.16 - 16.32 kgf.cm, 7.1 - 14.2 in..lbf)
Used bearing 0.5 - 1.0 N.m (5.10 - 10.20 kgf.cm, 4.4 - 8.9 in..lbf)
Output shaft rear bearing shim thickness 0 1.30 mm (0.0512 in.)
1 1.35 mm (0.0531 in.)
2 1.40 mm (0.0551 in.)
3 1.45 mm (0.0571 in.)
4 1.50 mm (0.0591 in.)
5 1.55 mm (0.0610 in.)
6 1.60 mm (0.0630 in.)
7 1.65 mm (0.0650 in.)
8 1.70 mm (0.0669 in.)
9 1.75 mm (0.0689 in.)
A 1.80 mm (0.0709 in.)
B 1.85 mm (0.0728 in.)
C 1.90 mm (0.0748 in.)
D 1.95 mm (0.0768 in.)
E 2.00 mm (0.0787 in.)
F 2.05 mm (0.0807 in.)
G 2.10 mm (0.0827 in.)
H 2.15 mm (0.0846 in.)
J 2.20 mm (0.0866 in.)
K 2.25 mm (0.0886 in.)
L 2.30 mm (0.0906 in.)
M 2.35 mm (0.0925 in.)
N 2.40 mm (0.0945 in.)
P 2.45 mm (0.0965 in.)
Q 2.50 mm (0.0984 in.)
Front differential case tapered roller bearing preload New bearing 0.8 - 1.6 N.m (8.16 - 16.32 kgf.cm, 7.1 - 14.2 in..lbf)
Used bearing 0.5 - 1.0 N.m (5.10 - 10.20 kgf.cm, 4.4 - 8.9 in..lbf)
Transmission case oil seal drive in depth 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
Front differential case shim RR thickness 0 2.00 mm (0.0787 in.)
1 2.05 mm (0.0807 in.)
2 2.10 mm (0.0827 in.)
3 2.15 mm (0.0846 in.)
4 2.20 mm (0.0866 in.)
5 2.25 mm (0.0886 in.)
6 2.30 mm (0.0906 in.)
7 2.35 mm (0.0925 in.)
8 2.40 mm (0.0945 in.)
9 2.45 mm (0.0965 in.)
A 2.50 mm (0.0984 in.)
B 2.55 mm (0.1004 in.)
C 2.60 mm (0.1024 in.)
D 2.65 mm (0.1043 in.)
E 2.70 mm (0.1063 in.)
F 2.75 mm (0.1083 in.)
G 2.80 mm (0.1102 in.)
H 2.85 mm (0.1122 in.)
Front differential case oil seal clearance 1 - 2 mm (0.0394 - 0.0787 in.)
Input shaft front bearing clearance 4.28 - 4.60 mm (0.1685 - 0.1811 in.)
Reverse restrict pin clearance 12.5 - 13.5 mm (0.492 - 0.531 in.)
Transmission clutch hub No.3 snap ring clearance 0.1 mm or less (0.0039 in. or less)
Transmission clutch hub No.3 snap ring thickness a 1.75 - 1.80 mm (0.0689 - 0.0709 in.)
b 1.80 - 1.85 mm (0.0709 - 0.0728 in.)
c 1.85 - 1.90 mm (0.0728 - 0.0748 in.)
d 1.90 - 1.95 mm (0.0748 - 0.0768 in.)
e 1.95 - 2.00 mm (0.0768 - 0.0787 in.)
f 2.00 - 2.05 mm (0.0787 - 0.0807 in.)
g 2.05 - 2.10 mm (0.0807 - 0.0827 in.)
h 2.10 - 2.15 mm (0.0827 - 0.0846 in.)
j 2.15 - 2.20 mm (0.0846 - 0.0866 in.)
5th gear radial clearance Standard clearance 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
5th gear thrust clearance Standard clearance 0.10 - 0.65 mm (0.0039 - 0.0260 in.)
Input shaft assy
4th gear thrust clearance Standard clearance 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
3rd gear thrust clearance Standard clearance 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
3rd gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
Input shaft run out Maximum run out: 0.03 mm (0.0012 in.)
Input shaft standard outer diameter A 35.984 - 36.000 mm (1.4167 - 1.4173 in.)
B 35.984 - 36.000 mm (1.4167 - 1.4173 in.)
C 27.957 - 27.972 mm (1.1007 - 1.1013 in.)
Input shaft minimum outer diameter A 35.984 mm (1.4167 in.)
B 35.984 mm (1.4167 in.)
C 27.957 mm (1.1007 in.)
4th gear inside diameter Standard inside diameter 42.09 - 42.025 mm (1.6539 -1.6545 in.)
Maximum inside diameter 42.025 mm (1.6545 in.)
3rd gear inside diameter Standard inside diameter 43.009 - 43.025 mm (1.6933 - 1.6939 in.)
Maximum inside diameter 43.025 mm (1.6939 in.)
Between the 4th gear spline end and synchronizer outer ring back clearance 0.75 - 1.65 mm (0.0295 - 0.0650 in.)
Between the 3rd gear spline end and synchronizer outer ring back clearance 0.65 - 1.75 mm (0.0256 - 0.0689 in.)
Transmission hub sleeve No.3 groove - thickness of the claw part on gear shift fork No.1    
Standard clearance 0.15 - 0.35 mm (0.0059 - 0.0138 in.)
Transmission clutch hub No.2 snap ring clearance Standard clearance 0.1 mm or less (0.0039 in. or less)
Transmission case oil seal drive in depth 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
Transmission clutch hub No.2 snap ring thickness H 2.30 - 2.35 mm (0.0906 - 0.0925 in.)
J 2.35 - 2.40 mm (0.0925 - 0.0945 in.)
K 2.40 - 2.45 mm (0.0945 - 0.0965 in.)
L 2.45 - 2.50 mm (0.0965 - 0.0984 in.)
M 2.50 - 2.55 mm (0.0984 - 0.1004 in.)
N 2.55 - 2.60 mm (0.1004 - 0.1024 in.)
P 2.60 - 2.65 mm (0.1024 - 0.1043 in.)
Input shaft rear radial ball bearing snap ring clearance Standard clearance 0.1 mm or less (0.0039 in. or less)
Input shaft rear radial ball bearing snap ring thickness 1 2.35 - 2.40 mm (0.0925 - 0.0945 in.)
2 2.40 - 2.45 mm (0.0945 - 0.0965 in.)
3 2.45 - 2.50 mm (0.0965 - 0.0984 in.)
4 2.50 - 2.55 mm (0.0984 - 0.1004 in.)
5 2.55 - 2.60 mm (0.1004 - 0.1024 in.)
6 2.60 - 2.65 mm (0.1024 - 0.1043 in.)
7 2.65 - 2.70 mm (0.1043 - 0.1063 in.)
8 2.70 - 2.75 mm (0.1063 - 0.1083 in.)
3rd gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
4th gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
3rd gear thrust clearance Standard clearance 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear thrust clearance Standard clearance 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Output shaft assy
1st gear thrust clearance Standard clearance 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
2nd gear thrust clearance Standard clearance 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
1st gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
2nd gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
Output shaft run out Maximum run out 0.03 mm (0.0012 in.)
Output shaft standard outer diameter A 37.610 - 37.626 mm (1.4807 -1.4813 in.)
B 34.802 - 34.512 mm (1.3702 - 1.3587 in.)
Output shaft minimum outer diameter A 37.610 mm (1.4807 in.)
B 34.802 mm (1.3702 in.)
2nd gear inside diameter Standard inside diameter 50.009 - 50.025 mm (1.9689 -1.9695 in.)
Maximum inside diameter 50.025 mm (1.9695 in.)
1st gear inside diameter Standard inside diameter 51.009 - 51.025 (2.0082 - 2.0089 in.)
Maximum inside diameter 51.025 mm (2.0089 in.)
Between the 2nd gear while and synchronizer ring No.2 back clearance 0.70 - 1.45 mm (0.0276 - 0.0571 in.)
Between the 1st gear while and synchronizer ring set No.1 back clearance 0.70 - 1.45 mm (0.0276 - 0.0571 in.)
Reverse gear groove - thickness of the claw part on gear shift fork No 1 clearance    
Standard clearance 0.15 - 0.35 mm (0.0059 - 0.0138 in.)
2nd gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
1st gear radial clearance KOYO made 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
NSK made 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
2nd gear thrust clearance Standard clearance 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
1st gear thrust clearance Standard clearance 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
Differential case assy
Front differential side gear backlash Standard backlash 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Front differential pinion thrust washer thickness Minimum thickness 0.9 mm (0.035 in.)
Front differential pinion shaft No.1 thickness Minimum thickness 17.975 mm (0.70768 in.)
Front differential side gear backlash Standard backlash 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Transmission case oil seal drive in depth 3.5 ± 0.5 mm (0.138 ± 0.020 in.)
Front differential side gear thrust washer thickness 1 1.00 mm (0.0394 in.)
2 1.10 mm (0.0433 in.)
3 1.20 mm (0.0472 in.)
4 1.30 mm (0.0512 in.)
Shift & select lever shaft assy
Control shaft cover bimetal formed bush drive in depth 0 ± 0.25 mm (0 ± 0.010 in.)
Control shaft cover oil seal drive in depth 28.5 ± 0.50 mm (1.122 ± 0. 020 in.)
Shift lever slotted pin clearance to the shift lever inner assy -0.5 - 0.5 mm (- 0.0197 - 0.0197 in.)
Shift lever slotted pin clearance to the shift lever inner No.2 5.8 - 6.8 mm (0.228 - 0.268 in.)
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