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Manual Transmission and M/T Differential

Item
Measurement
Qualification
Standard or New
Service Limit
Manual transmission fluid
Capacity
Use genuine Honda MTF
Fluid change
1.5 L (1.6 US qt, 1.3 Imp qt)
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 (transmission housing side)
25.987−26.000 mm (1.0231−1.0236 in.)
25.93 mm (1.020 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 (clutch housing side)
25.977−25.990 mm (1.0227−1.0232 in.)
25.92 mm (1.020 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 gear
I.D.
39.009−39.025 mm (1.5358−1.5364 in.)
39.07 mm (1.538 in.)
Clearance
2nd-3rd
0.06−0.21 mm (0.002−0.008 in.)
0.33 mm (0.013 in.)
Endplay
4th
0.06−0.19 mm (0.002−0.007 in.)
0.31 mm (0.012 in.)
Thickness
3rd
27.92−27.97 mm (1.099−1.101 in.)
27.85 mm (1.096 in.)
4th
27.02−27.07 mm (1.064−1.066 in.)
26.65 mm (1.049 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.)
Mainshaft 4th and 5th gear 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
A
51.97−52.03 mm (2.046−2.048 in.)
———
B
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.)
———


Manual Transmission and M/T Differential (cont'd)

Item
Measurement
Qualification
Standard or New
Service Limit
Countershaft
Diameter of needle bearing contact area (transmission housing side)
34.000−34.015 mm (1.3386−1.3392 in.)
33.95 mm (1.337 in.)
Diameter of ball bearing contact area (clutch housing side)
24.980−24.993 mm (0.9835−0.9840 in.)
24.93 mm (0.981 in.)
Diameter of distance collar contact area
36.487−36.500 mm (1.4365−1.4370 in.)
36.44 mm (1.4346 in.)
Runout
0.02 mm (0.001 in.) max.
0.05 mm (0.002 in.)
Countershaft 1st gear
I.D.
48.509−48.525 mm (1.9098−1.9104 in.)
48.580 mm (1.9126 in.)
End play
0.03−0.12 mm (0.001−0.005 in.)
0.24 mm (0.009 in.)
Thickness
27.42−27.47 mm (1.080−1.081 in.)
27.39 mm (1.078 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 1st gear distance collar
I.D.
36.50−36.51 mm (1.4370−1.4373 in.)
36.52 mm (1.4378 in.)
O.D.
44.489−45.000 mm (1.7515−1.7717 in.)
44.44 mm (1.7500 in.)
Length
A
30.50−30.54 mm (1.2007−1.2023 in.)
———
B
26.53−26.58 mm (1.044−1.046 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.)
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 fork
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
Finger width
13.5−13.8 mm (0.53−0.54 in.)
———
Fork-to-reverse idler gear clearance
1.30−1.90 mm (0.051−0.075 in.)
2.5 mm (0.098 in.)
Shift arm
I.D.
13.973−14.000 mm (0.5501−0.5512 in.)
———
Finger width
12.9−13.0 mm (0.508−0.512 in.)
———
Shift arm-to-shift fork 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.)
———
Change lever
Shaft-to-select lever clearance
0.05−0.35 mm (0.002−0.014 in.)
0.55 mm (0.022 in.)
Groove width
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 pinion gear
Backlash
0.05−0.15 mm (0.002−0.006 in.)
———
M/T differential 72 mm shim
(L13Z1, L13Z3)
72 mm shim-to-bearing outer race clearance in transmission housing
0.01−0.1 mm (0.0004−0.004 in.)
Adjust
M/T differential 80 mm shim
(L15A7, L15A8)
80 mm shim-to-bearing outer race clearance in transmission housing
0.01−0.1 mm (0.0004−0.004 in.)
Adjust