Manual Transmission and M/T Differential
Item Measurement Qualification Standard or New Service Limit 
Transmission fluid Capacity 4WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt) 
4WD at overhaul 2.3 L (2.4 US qt, 2.0 Imp qt) 
2WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt) 
2WD at overhaul 2.1 L (2.2 US qt, 1.8 Imp qt)  
Mainshaft End play  0.11-0.17 mm (0.004-0.007 in.) Adjust 
Diameter of bushing surface  20.80-20.85 mm (0.8189-0.8209 in.) 20.75 mm (0.817 in.) 
Diameter of distance collar  31.984-32.000 mm (1.2594-1.2598 in.) 31.93 mm (1.257 in.) 
Diameter of ball bearing contact area
(clutch housing side) 
 27.977-27.990 mm (1.1015-1.1020 in.) 27.94 mm (1.100 in.) 
Diameter of needle bearing contact area  38.984-39.000 mm (1.5348-1.5354 in.) 38.93 mm (1.533 in.) 
Diameter of ball bearing contact area
(transmission housing side) 
 27.987-28.000 mm (1.1019-1.1024 in.) 27.94 mm (1.100 in.) 
Runout  0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 
Mainshaft 3rd, 4th and 5th gears I.D.  44.009-44.025 mm (1.7326-1.7333 in.) 44.08 mm (1.735 in.) 
End play  0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) 
Thickness  23.92-23.97 mm (0.981-0.944 in.) 23.80 mm (0.937 in.) 
Countershaft Diameter of needle bearing contact area (clutch housing side)  35.000-35.015 mm (1.3780-1.3785 in.) 34.95 mm (1.376 in.) 
Diameter of distance collar contact area  39.937-39.950 mm (1.5723-1.5728 in.) 39.88 mm (1.570 in.) 
Diameter of ball bearing contact area (transmission housing side)  30.020-30.033 mm (1.1819-1.1824 in.) 29.97 mm (1.180 in.) 
Run out  0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 
35 mm shim-to-bearing inner race clearance  0.04-0.10 mm (0.0016-0.0039 in.) Adjust 
Countershaft 1st gear I.D.  52.010-52.029 mm (2.0476-2.0484 in.) 52.08 mm (2.050 in.) 
End play  0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) 
Thickness  22.92-22.97 mm (0.902-0.904 in.) 22.87 mm (0.900 in.) 
Countershaft 2nd gear I.D.  52.010-52.029 mm (2.0476-2.0484 in.) 52.08 mm (2.050 in.) 
End play  0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) 
Thickness  27.92-27.97 mm (1.099-1.101 in.) 27.87 mm (1.097 in.) 
Countershaft 1st gear distance collar I.D.  39.95-39.96 mm (1.5728-1.5732 in.) 39.97 mm (1.574 in.) 
O.D.  46.989-47.000 mm (1.8499-1.8504 in.) 46.94 mm (1.848 in.) 
Length  23.03-23.08 mm (0.907-0.909 in.) ——— 
Countershaft 2nd gear distance collar I.D.  39.95-39.96 mm (1.5728-1.5732 in.) 39.97 mm (1.574 in.) 
O.D.  46.989-47.000 mm (1.8499-1.8504 in.) 46.94 mm (1.848 in.) 
Length  28.03-28.08 mm (1.104-1.106 in.) ——— 
Mainshaft 4th and 5th gears distance collar I.D.  32.00-32.01 mm (1.2598-1.2602 in.) 32.02 mm (1.261 in.) 
O.D.  38.989-39.000 mm (1.5350-1.5354 in.) 38.94 mm (1.533 in.) 
Length

 

 
A

 
51.95-52.05 mm (2.045-2.049 in.) ——— 
24.03-24.08 mm (0.946-0.947 in.) ——— 
MBS distance collar I.D.  28.00-28.01 mm (1.102-1.103 in.) 28.02 mm (1.103 in.) 
Length  23.95-24.05 mm (0.943-0.947 in.) ——— 

Manual Transmission and M/T Differential (cont'd)
Item Measurement Qualification Standard or New Service Limit 
Reverse idler gear I.D.  20.016-20.043 mm (0.7880-0.7891 in.) 20.90 mm (0.832 in.) 
Gear-to-reverse gear shaft clearance  0.036-0.084 mm (0.0014-0.0033 in.) 0.16 mm (0.006 in.) 
Synchro ring Ring-to-gear clearance Ring pushed against gear 0.70-1.49 mm (0.028-0.059 in.) 0.4 mm (0.016 in.) 
Double cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) 
Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) 
Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) 
Triple cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) 
Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) 
Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) 
Shift fork Finger thickness  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 thinkness  13.4-13.7 mm (0.527-0.539 in.) ——— 
Fork-to-reverse idler gear clearance  0.20-0.59 mm (0.007-0.024 in.) 1.2 mm (0.047 in.) 
Shift arm I.D.  13.973-14.000 mm (0.5501-0.5512 in.) ——— 
Shift fork diameter at contact area  16.9-17.0 mm (0.665-0.669 in.) ——— 
Shift arm-to-shift lever clearance  0.2-0.5 mm (0.008-0.020 in.) 0.60 mm (0.023 in.) 
Select lever Finger width  14.85-14.95 mm (0.585-0.589 in.) ——— 
Shift lever Shaft-to-select lever clearance  0.05-0.25 mm (0.002-0.010 in.) 0.50 mm (0.020 in.) 
Groove (to select lever)  15.00-15.10 mm (0.591-0.594 in.) ——— 
Shaft-to-shift arm clearance  0.013-0.07 mm (0.0005-0.003 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  0.027-0.057 mm (0.0011-0.0022 in.) 0.1 mm (0.004 in.) 
Driveshaft contact area I.D.  28.025-28.045 mm (1.1033-1.1041 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  0.059-0.095 mm (0.0023-0.0037 in.) 0.15 mm (0.006 in.) 
80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing  0-0.10 mm (0-0.0039 in.) Adjust 
Transfer Diameter of tapered roller bearing contact area (transfer shaft)  24.975-24.990 mm (0.9833-0.9838 in.) 24.92 mm (0.9811 in.) 
Diameter of tapered roller bearing contact area (transfer drive gear)  40.002-40.018 mm (1.5749-1.5755 in.) 38.95 mm (1.5335 in.) 
Diameter of tapered roller bearing contact area (driven gear side)  35.002-35.018 mm (1.3780-1.3786 in.) 34.95 mm (1.3760 in.) 
Diameter of tapered roller bearing contact area (splined side)  26.975-26.988 mm (1.0620-1.0625 in.) 26.92 mm (1.0598 in.) 
Transfer gear backlash  0.06-0.16 mm (0.0024-0.0063 in.) Adjust 
Total starting torque  2.24-3.71 N·m (22.0-36.4 kgf·cm, 19.1-31.6 lbf·in.) Adjust