Standards and Service Limits

Manual Transmission and Differential

2-7  
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 spacer collar contact area   28.980-28.993 mm

(1.1409-1.1415 in.)

28.930 mm

(1.1390 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

(1.020 in.)

Run out   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.)

39.070 mm

(1.5382 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.)

39.070 mm

(1.5382 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

(1.3366 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.)

Run out   0.02 mm

(0.001 in.) max.

0.05 mm

(0.002 in.)

Countershaft 1st gear I.D.   43.009-43.025 mm

(1.6932-1.6939 in.)

43.070 mm

(1.6957 in.)

Endplay   0.03-0.10 mm

(0.001-0.039 in.)

0.22 mm

(0.009 in.)

Thickness   26.91-26.94 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.)

45.070 mm

(1.7744 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 spacer collar I.D.   34.000-34.010 mm

(1.3386-1.3390 in.)

34.040 mm

(1.3402 in.)

O.D.   39.989-40.000 mm

(1.5744-1.5748 in.)

39.930 mm

(1.5720 in.)

Length   27.53-27.56 mm

(1.084-1.085 in.)

27.51 mm

(1.083 in.)