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Manual Transmission and M/T Differential (i-SHIFT)

Item
Measurement
Qualification
Standard or New
Service Limit
Manual transmission fluid
Capacity
Use genuine Honda MTF
Fluid change
1.4 L (1.5 US qt, 1.2 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 bushing surface
14.870−14.890 mm (0.5854−0.5862 in.)
14.77 mm (0.5815 in.)
Diameter of distance collar
28.992−29.005 mm (1.1414−1.1419 in.)
28.93 mm (1.139 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 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)
24.987−25.000 mm (0.9837−0.9843 in.)
24.93 mm (0.981 in.)
Runout
0.02 mm (0.001 in.) max.
0.05 mm (0.002 in.)
Mainshaft 3rd, 4th, 5th, and 6th gears
I.D.
3rd/4th/5th
39.009−39.025 mm (1.5358−1.5364 in.)
38.95 mm (1.533 in.)
6th
35.009−35.025 mm (1.3783−1.3789 in.)
34.95 mm (1.376 in.)
Clearance
2nd-3rd
0.06−0.21 mm (0.002−0.008 in.)
0.30 mm (0.012 in.)
End play
4th
0.06−0.19 mm (0.002−0.007 in.)
0.28 mm (0.011 in.)
5th
0.06−0.14 mm (0.002−0.006 in.)
0.23 mm (0.009 in.)
6th
0.06−0.16 mm (0.002−0.006 in.)
0.25 mm (0.010 in.)
Thickness
3rd
27.02−27.07 mm (1.064−1.066 in.)
26.95 mm (1.061 in.)
4th
25.52−25.57 mm (1.005−1.007 in.)
25.45 mm (1.002 in.)
5th
22.42−22.47 mm (0.883−0.885 in.)
22.35 mm (0.880 in.)
6th
23.92−23.97 mm (0.942−0.944 in.)
23.85 mm (0.939 in.)
Mainshaft 4th/5th gears distance collar
I.D.
29.014−29.024 mm (1.1423−1.1427 in.)
29.03 mm (1.143 in.)
O.D.
34.989−35.000 mm (1.3775−1.3780 in.)
34.94 mm (1.376 in.)
Length
A
48.97−49.03 mm (1.9279−1.9303 in.)
———
B
22.53−22.56 mm (0.887−0.888 in.)
———
Mainshaft 6th gear distance collar
I.D.
25.00−25.01 mm (0.984−0.985 in.)
25.12 mm (0.989 in.)
Length
24.03−24.08 mm (0.946−0.948 in.)
———
Countershaft
Diameter of ball bearing contact area (transmission housing side)
26.020−26.033 mm (1.0244−1.0249 in.)
25.97 mm (1.022 in.)
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 distance collar contact area
38.987−39.000 mm (1.5349−1.5354 in.)
38.94 mm (1.533 in.)
Runout
0.02 mm (0.001 in.) max.
0.05 mm (0.002 in.)
32 mm shim-to-bearing inner race clearance
0.04−0.10 mm (0.0016−0.0039 in.)
Adjust
Countershaft 1st gear
I.D.
48.509−48.525 mm (1.9098−1.9104 in.)
48.58 mm (1.913 in.)
End play
0.06−0.16 mm (0.002−0.006 in.)
0.25 mm (0.010 in.)
Thickness
21.42−21.47 mm (0.843−0.845 in.)
———
Countershaft 2nd gear
I.D.
48.509−48.525 mm (1.9098−1.9104 in.)
48.52 mm (1.910 in.)
End play
0.06−0.14 mm (0.002−0.006 in.)
0.23 mm (0.009 in.)
Thickness
26.42−26.47 mm (1.040−1.042 in.)
———


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

Item
Measurement
Qualification
Standard or New
Service Limit
Countershaft 1st gear distance collar
I.D.
39.00−39.01 mm (1.5354−1.5358 in.)
39.02 mm (1.536 in.)
O.D.
44.489−44.500 mm (1.7515−1.7520 in.)
44.44 mm (1.750 in.)
Length
21.53−21.58 mm (0.848−0.850 in.)
———
Countershaft 2nd gear distance collar
I.D.
39.00−39.01 mm (1.5354−1.5358 in.)
39.02 mm (1.536 in.)
O.D.
44.489−44.5 mm (1.7515−1.7520 in.)
44.44 mm (1.750 in.)
Length
26.53−26.56 mm (1.044−1.046 in.)
———
Reverse idler gear
I.D.
18.016−18.043 mm (0.7093−0.7104 in.)
18.08 mm (0.712 in.)
Gear-to-reverse gear shaft clearance
0.032−0.077 mm (0.0013−0.003 in.)
0.14 mm (0.006 in.)
Synchro ring
Ring-to-gear clearance
Ring pushed against gear
0.655−1.334 mm (0.026−0.053 in.)
0.4 mm (0.016 in.)
Shift fork
Finger thickness
1st-2nd fork
6.7−6.9 mm (0.26−0.27 in.)
———
3rd-4th and 5th-6th fork
7.4−7.6 mm (0.29−0.30 in.)
———
Fork-to-synchro sleeve clearance
0.35−0.65 mm (0.014−0.026 in.)
1.0 mm (0.039 in.)
Reverse shift fork
Finger width
14.7−14.9 mm (0.527−0.587 in.)
———
Fork-to-reverse idler gear clearance
0.20−0.60 mm (0.007−0.024 in.)
1.2 mm (0.047 in.)
Shift arm
I.D.
14.013−14.058 mm (0.5517−0.5535 in.)
———
Shift piece diameter at contact area
0.20−0.60 mm (0.008−0.024 in.)
0.7 mm (0.028 in.)
Shift arm-to-change lever clearance
0.013−0.085 mm (0.0005−0.0033 in.)
———
Select lever
O.D.
13.941−13.968 mm (0.5489−0.5499 in.)
———
Shift arm cover clearance
0.032−0.127 mm (0.0013−0.0050 in.)
———
Inter lock
I.D.
14.000−14.077 mm (0.5512−0.5542 in.)
———
Inter lock to select lever
0.032−0.136 mm (0.0013−0.0054 in.)
———
Shift piece
I.D.
14.000−14.068 mm (0.5512−0.5539 in.)
———
Shift-piece-to select lever clearance
0.032−0.127 mm (0.0013−0.0050 in.)
———
Shift fork diameter at contact area
0.2−0.5 mm (0.008−0.020 in.)
———
M/T differential pinion gear
Backlash
0.05−0.15 mm (0.002−0.006 in.)
———
M/T differential 80 mm shim
80 mm shim-to-bearing outer race clearance in transmission housing
0.01−0.10 mm (0.0004−0.0039 in.)
Adjust