Manual Transmission and M/T Differential
Item Measurement Qualification Standard or New Service Limit 
Transmission fluid Capacity
Use Honda MTF 
Fluid change 2.2 L (2.3 US qt, 1.3 Imp qt) 
Overhaul 2.5 L (2.6 US qt, 1.4 Imp qt) 
Mainshaft End play  0.14-0.21 mm (0.006-0.008 in.) Adjust 
Diameter of pilot bearing surface  19.967-19.980 mm (0.7861-0.7866 in.) 19.91 mm (0.784 in.) 
Diameter of 4th and 5th gears
distance collar 
 35.987-36.000 mm (1.4168-1.4173 in.) 35.93 mm (1.415 in.) 
Diameter of ball bearing contact area
(clutch housing side) 
 28.002-28.015 mm (1.1024-1.1030 in.) 27.95 mm (1.100 in.) 
Diameter of needle bearing contact area  41.984-42.000 mm (1.6529-1.6535 in.) 41.93 mm (1.651 in.) 
Diameter of 6th gear distance collar  32.987-33.000 mm (1.2987-1.2992 in.) 32.93 mm (1.296 in.) 
Diameter of ball bearing contact area
(transmission housing side) 
 30.987-31.000 mm (1.2200-1.2205 in.) 30.93 mm (1.218 in.) 
Runout  0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 
Mainshaft 3rd gear I.D.  47.009-47.025 mm (1.8507-1.8514 in.) 47.08 mm (1.854 in.) 
End play  0.06-0.19 mm (0.002-0.007 in.) 0.3 mm (0.01 in.) 
Thickness  23.89-23.97 mm (0.941-0.944 in.) 23.8 mm (0.94 in.) 
Mainshaft 4th and 5th gears I.D.  47.009-47.025 mm (1.8507-1.8514 in.) 47.08 mm (1.854 in.) 
End play  0.06-0.19 mm (0.002-0.007 in.) 0.3 mm (0.01 in.) 
Thickness  22.39-22.47 mm (0.881-0.885 in.) 22.3 mm (0.88 in.) 
Mainshaft 6th gear I.D.  44.009-44.025 mm (1.7326-1.7333 in.) 44.08 mm (1.735 in.) 
End play  0.06-0.19 mm (0.002-0.007 in.) 0.3 mm (0.01 in.) 
Thickness  21.89-21.97 mm (0.862-0.865 in.) 21.8 mm (0.86 in.) 
Countershaft Diameter of needle bearing contact area (clutch housing side)  43.974-43.990 mm (1.7313-1.7319 in.) 43.92 mm (1.729 in.) 
Diameter of distance collar contact area  42.975-42.991 mm (1.6919-1.6926 in.) 42.92 mm (1.690 in.) 
Diameter of ball bearing contact area (transmission housing side)  30.002-30.015 mm (1.1812-1.1817 in.) 29.95 mm (1.179 in.) 
Diameter of countershaft reverse gear  45.934-45.950 mm (1.8084-1.8091 in.) 45.88 mm (1.806 in.) 
Runout  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.  57.010-57.029 mm (2.2445-2.2452 in.) 57.08 mm (2.247 in.) 
End play  0.04-0.17 mm (0.002-0.007 in.) 0.28 mm (0.011 in.) 
Thickness  22.91-22.99 mm (0.902-0.905 in.) 22.86 mm (0.900 in.) 
Countershaft 2nd gear I.D.  57.010-57.029 mm (2.2445-2.2452 in.) 57.08 mm (2.247 in.) 
End play  0.04-0.17 mm (0.002-0.007 in.) 0.28 mm (0.011 in.) 
Thickness  22.91-22.99 mm (0.902-0.905 in.) 22.86 mm (0.900 in.) 
Countershaft reverse gear I.D.  45.970-45.988 mm (1.8098-1.8105 in.) 46.04 mm (1.813 in.) 
O.D.  51.987-52.000 mm (2.0467-2.0472 in.) 51.93 mm (2.044 in.) 
Length  23.03-23.08 mm (0.907-0.909 in.) ——— 
Countershaft 2nd gear distance collar I.D.  42.990-43.000 mm (1.6925-1.6929 in.) 43.05 mm (1.695 in.) 
O.D.  51.989-52.000 mm (2.0468-2.0472 in.) 51.94 mm (2.045 in.) 
Length  23.03-23.08 mm (0.907-0.909 in.) ——— 

Manual Transmission and M/T Differential (cont'd)
Item Measurement Qualification Standard or New Service Limit 
Mainshaft 4th and 5th gears distance collar I.D.  36.002-36.012 mm (1.4174-1.4178 in.) 36.06 mm (1.420 in.) 
O.D.  41.989-42.000 mm (1.6531-1.6535 in.) 41.94 mm (1.651 in.) 
Length

 

 
A


 
49.95-50.05 mm (1.967-1.970 in.) ——— 
22.53-22.58 mm (0.887-0.889 in.) ——— 
Mainshaft 6th gear distance collar I.D.  33.002-33.012 mm (1.2993-1.2997 in.) 33.06 mm (1.302 in.) 
O.D.  38.989-39.000 mm (1.5350-1.5354 in.) 38.94 mm (1.533 in.) 
Length  22.03-22.08 mm (0.867-0.869 in.) ——— 
Reverse shaft O.D.  19.989-20.000 mm (0.7870-0.7874 in.) 19.93 mm (0.785 in.) 
Reverse drive/driven gear I.D.  25.007-25.020 mm (0.9845-0.9850 in.) 25.07 mm (0.987 in.) 
5th 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.) 
6th synchro ring Ring-to-gear clearance Ring pushed against gear 0.73-1.44 mm (0.029-0.057 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.) 
1st 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 0.45-1.14 mm (0.018-0.045 in.) 0.3 mm (0.012 in.) 
Outer synchro ring-to-gear cone clearance Ring pushed against gear 1.12-1.68 mm (0.044-0.066 in.) 0.6 mm (0.024 in.) 
2nd 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 0.60-1.88 mm (0.024-0.074 in.) 0.3 mm (0.012 in.) 
Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.87-1.82 mm (0.034-0.072 in.) 0.6 mm (0.024 in.) 
1st/2nd,
3rd/4th,
5th/6th 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 thickness  6.2-6.4 mm (0.24-0.25 in.) ——— 
Fork-to-synchro sleeve clearance  0.35-0.65 mm (0.014-0.026 in.) 1.0 mm (0.039 in.) 
Reverse shift lever Finger thickness  6.400-6.650 mm (0.2520-0.2618 in.) ——— 
Shift lever-to-shift fork clearance  0.05-0.50 mm (0.002-0.020 in.) 0.6 mm (0.024 in.) 
Shift lever diameter at contact area  13.0-13.2 mm (0.51-0.52 in.) ——— 
Shift lever-to-interlock clearance  0-0.4 mm (0-0.015 in.) 0.5 mm (0.020 in.) 
Shift piece I.D.  14.000-14.068 mm (0.5512-0.5539 in.) ——— 
Shift fork diameter at contact area  12.8-13.0 mm (0.50-0.51 in.) ——— 
Shift piece-to-shift fork clearance  0.2-0.6 mm (0.008-0.024 in.) 0.7 mm (0.028 in.)