Clutch
Item Measurement Qualification Standard or New Service Limit 
Clutch pedal Height from floor  200 mm (7.87 in.) ——— 
Stroke  125-135 mm (4.92-5.31 in.) ——— 
Play  6-17 mm (0.24-0.67 in.) ——— 
Disengagement height from floor  112 mm (4.41 in.) max. ——— 
Flywheel Runout on clutch mating surface  0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.) 
Clutch disc Rivet head depth  1.65-2.25 mm (0.065-0.089 in.) 0.7 mm (0.03 in.) 
Thickness  8.7-9.3 mm (0.34-0.37 in.) 6.0 mm (0.24 in.) 
Pressure plate Warpage  0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.) 
Height of diaphragm spring fingers measured with special tool and feeler gauge  0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.) 

Manual Transmission and M/T Differential
Item Measurement Qualification Standard or New Service Limit 
Transmission fluid Capacity
Use Honda MTF 
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 (0.942-0.944 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.) 
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.  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 thickness  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  0.013-0.070 mm (0.0005-0.0028 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