Manual Transmission and Differential
Item Measurement Qualification Standard or New Service Limit 
Transmission oil Capacity  For fluid change: 1.5 L (1.6 US qt, 1.3 Imp qt)  
For overhaul: 1.6 L (1.7 US qt, 1.4 Imp 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.) 
4th 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.) 

Manual Transmission and Differential (cont'd)
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

 

 
51.97-52.03 mm
(2.046-2.048 in.) 
——— 
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