1. MANUAL TRANSMISSION AND DIFFERENTIAL
|
Model |
2.0 L non-turbo |
2.5 L non-turbo |
2.5 L Turbo | |||
|
EC EK ER |
EC EK ER Excluding above models | |||||
|
Type |
5 × 2-forward speeds with synchromesh and 2-reverse |
5-forward speeds with synchromesh and 1-reverse | ||||
|
Transmission gear ratio |
1st |
3.454 | ||||
|
2nd |
2.062 |
1.947 | ||||
|
3rd |
1.448 |
1.366 | ||||
|
4th |
1.088 |
0.972 | ||||
|
5th |
0.871 |
0.780 |
0.738 | |||
|
Reverse |
3.333 | |||||
|
Auxiliary transmission gear ratio |
High |
1.000 |
— | |||
|
Low |
1.447 |
1.196 |
— | |||
|
Front reduction gear |
Final |
Type of gear |
Hypoid | |||
|
Gear ratio |
4.111 |
4.444 | ||||
|
Rear reduction gear |
Transfer |
Type of gear |
Helical | |||
|
Gear ratio |
1.000 |
1.801 |
1.000 | |||
|
Final |
Type of gear |
Hypoid | ||||
|
Gear ratio |
4.111 |
4.111 |
4.444 | |||
|
Front differential |
Type and number of gear |
Straight bevel gear (bevel pinion: 2, bevel gear: 2) | ||||
|
Center differential |
Type and number of gear |
Straight bevel gear (bevel pinion: 2, bevel gear: 2 and viscous coupling) | ||||
|
Transmission gear oil |
GL-5 | |||||
|
Transmission gear oil capacity |
4.0 L (4.2 US qt, 3.5 Imp qt) |
3.5 L (3.7 US qt, 3.1 Imp qt) | ||||
*: For option codes, refer to the ID section. 
Recommended oil:
GL-5 (75W-90) or equivalent
Drive pinion shim adjustment
Hypoid gear backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
|
Drive pinion shim | |||
|
Part number |
Thickness mm (in) |
Part number |
Thickness mm (in) |
|
32295AA031 |
0.150 (0.0059) |
32295AA071 |
0.250 (0.0098) |
|
32295AA041 |
0.175 (0.0069) |
32295AA081 |
0.275 (0.0108) |
|
32295AA051 |
0.200 (0.0079) |
32295AA091 |
0.300 (0.0118) |
|
32295AA061 |
0.225 (0.0089) |
32295AA101 |
0.500 (0.0197) |
Selection of main shaft rear plate
|
Main shaft rear plate | ||
|
Dimension “A” mm (in) |
Part number |
Mark |
|
4.00 — 4.13 (0.1575 — 0.1626) |
32294AA041 |
1 |
|
3.87 — 3.99 (0.1524 — 0.1571) |
32294AA051 |
2 |
Clearance between snap ring and counter washer:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
|
Snap ring (Outer-19) | |
|
Part number |
Thickness mm (in) |
|
031319000 |
1.50 (0.0591) |
|
805019010 |
1.72 (0.0677) |
Input shaft holder adjustment.
|
Dimension D mm (in) |
Number of shims |
|
52.50 — 53.11 (2.0669 — 2.0909) |
— |
|
52.00 — 52.49 (2.0472 — 2.0665) |
1 |
|
51.26 — 51.99 (2.0181 — 2.0468) |
2 |
Preload adjustment of thrust bearing
Starting torque:
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-lb)
|
Adjusting washer No. 1 | |
|
Part number |
Thickness mm (in) |
|
803025051 |
3.925 (0.1545) |
|
803025052 |
3.950 (0.1555) |
|
803025053 |
3.975 (0.1565) |
|
803025054 |
4.000 (0.1575) |
|
803025055 |
4.025 (0.1585) |
|
803025056 |
4.050 (0.1594) |
|
803025057 |
4.075 (0.1604) |
|
Adjusting washer No. 2 | |
|
Part number |
Thickness mm (in) |
|
803025059 |
3.850 (0.1516) |
|
803025054 |
4.000 (0.1575) |
|
803025058 |
4.150 (0.1634) |
Clearance between snap ring (outer 28) to ball bearing:
0 — 0.12 mm (0 — 0.0047 in)
|
Snap ring (Outer-28) | |
|
Part number |
Thickness mm (in) |
|
805028050 |
2.48 (0.0976) |
|
805028060 |
2.56 (0.1008) |
|
805028070 |
2.64 (0.1039) |
Clearance between snap ring (inner 68) to bearing:
0 — 0.12 mm (0 — 0.0047 in)
|
Snap ring (Inner 68) | |
|
Part number |
Thickness mm (in) |
|
805168020 |
1.84 (0.0724) |
|
805168030 |
1.92 (0.0756) |
|
805168040 |
2.00 (0.0787) |
Clearance between snap ring (outer 25) to synchronizer hub:
0.060 — 0.100 mm (0.0024 — 0.0039 in)
|
Snap ring (Outer-25) | |||
|
Part number |
Thickness mm (in) |
Part number |
Thickness mm (in) |
|
805025051 |
2.42 (0.0953) |
805025055 |
2.62 (0.1031) |
|
805025052 |
2.47 (0.0972) |
805025056 |
2.67 (0.1051) |
|
805025053 |
2.52 (0.0992) |
805025057 |
2.72 (0.1071) |
|
805025054 |
2.57 (0.1012) |
805025058 |
2.37 (0.0933) |
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance:
6.0 — 7.5 mm (0.236 — 0.295 in)
|
Reverse shifter lever | ||
|
Part number |
Mark |
Remarks |
|
32820AA070 |
7 |
Further from case wall |
|
32820AA080 |
8 |
Standard |
|
32820AA090 |
9 |
Closer to the case wall |
After installing a suitable reverse shifter lever, adjust the clearance using washers.
Reverse idler gear to transmission case wall clearance:
0 — 0.5 mm (0 — 0.020 in)
|
Washer (20.5 × 26 × t) | |||
|
Part number |
Thickness mm (in) |
Part number |
Thickness mm (in) |
|
803020151 |
0.4 (0.016) |
803020154 |
1.9 (0.075) |
|
803020152 |
1.1 (0.043) |
803020155 |
2.3 (0.091) |
|
803020153 |
1.5 (0.059) |
— |
— |
Select a suitable shifter fork so that both the coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.
Rod end clearance:
A: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
B: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
|
1st-2nd shifter fork | ||
|
Part number |
Mark |
Remarks |
|
32804AA060 |
1 |
Approaches 1st gear by 0.2 mm (0.008 in). |
|
32804AA070 |
No mark |
Standard |
|
32804AA080 |
3 |
Approaches 2nd gear by 0.2 mm (0.008 in) |
|
3rd-4th shifter fork | ||
|
Part number |
Mark |
Remarks |
|
32810AA061 |
1 |
Approaches 4th gear by 0.2 mm (0.008 in). |
|
32810AA071 |
No mark |
Standard |
|
32810AA101 |
3 |
Approaches 3rd gear by 0.2 mm (0.008 in) |
|
5th shifter fork (non-turbo) & identification paint (pink) | ||
|
Part number |
Mark |
Remarks |
|
32812AA201 |
7 |
Approaches 5th gear by 0.2 mm (0.008 in). |
|
32812AA211 |
No mark |
Standard |
|
32812AA221 |
9 |
Moves away from 5th gear by 0.2 mm (0.008 in). |
|
5th shifter fork (turbo) & identification paint (blue) | ||
|
Part number |
Mark |
Remarks |
|
32812AA231 |
7 |
Approaches 5th gear by 0.2 mm (0.008 in). |
|
32812AA241 |
No mark |
Standard |
|
32812AA251 |
9 |
Moves away from 5th gear by 0.2 mm (0.008 in). |
Neutral position adjustment
|
Adjusting shim | |
|
Part number |
Thickness mm (in) |
|
32190AA000 |
0.15 (0.0059) |
|
32190AA010 |
0.30 (0.0118) |
|
Reverse accent shaft | ||
|
Part number |
Mark |
Remarks |
|
32188AA130 |
S |
Neutral position is closer to 1st. |
|
32188AA140 |
T |
Standard |
|
32188AA150 |
U |
Neutral position is closer to reverse gear. |
Reverse check plate adjustment
|
Reverse check plate | |||
|
Part number |
Mark |
Angleθ |
Remarks |
|
32189AA000 |
0 |
28° |
Arm stops closer to 5th gear. |
|
32189AA010 |
1 |
31° |
Arm stops closer to 5th gear. |
|
33189AA020 |
2 |
34° |
Arm stops in the center. |
|
32189AA030 |
3 |
37° |
Arm stops closer to reverse gear. |
|
32189AA040 |
4 |
40° |
Arm stops closer to reverse gear. |
Taper roller bearing preload (standard protrusion amount):
0.2 — 0.3 mm (0.0008 — 0.012 in)
NOTE:
Be sure that the preload is always within the standard.
|
Thrust washer (50 × 61 × t) | |
|
Part number |
Thickness mm (in) |
|
803050060 |
0.50 (0.0197) |
|
803050061 |
0.55 (0.0217) |
|
803050062 |
0.60 (0.0236) |
|
803050063 |
0.65 (0.0256) |
|
803050064 |
0.70 (0.0276) |
|
803050065 |
0.75 (0.0295) |
|
803050066 |
0.80 (0.0315) |
|
803050067 |
0.85 (0.0335) |
|
803050068 |
0.90 (0.0354) |
|
803050069 |
0.95 (0.0374) |
|
803050070 |
1.00 (0.0394) |
|
803050071 |
1.05 (0.0413) |
|
803050072 |
1.10 (0.0433) |
|
803050073 |
1.15 (0.0453) |
|
803050074 |
1.20 (0.0472) |
|
803050075 |
1.25 (0.0492) |
|
803050076 |
1.30 (0.0512) |
|
803050077 |
1.35 (0.0531) |
|
803050078 |
1.40 (0.0551) |
|
803050079 |
1.45 (0.0571) |
Thrust washer to center differential side clearance:
0.15 — 0.35 mm (0.0059 — 0.0138 in)
|
Thrust washer | |
|
Part number |
Thickness mm (in) |
|
803036050 |
0.9 (0.035) |
|
803036054 |
1.0 (0.039) |
|
803036051 |
1.1 (0.043) |
|
803036055 |
1.2 (0.047) |
|
803036052 |
1.3 (0.051) |
|
803036056 |
1.4 (0.055) |
|
803036053 |
1.5 (0.059) |
|
803036057 |
1.6 (0.063) |
|
803036058 |
1.7 (0.067) |
Bevel gear to pinion backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
|
Washer (38.1 × 50 × t) | |||
|
Part number |
Thickness mm (in) |
Part number |
Thickness mm (in) |
|
803038021 |
0.925 — 0.950 (0.0364 — 0.0374) |
803038023 |
1.025 — 1.050 (0.0404 — 0.0413) |
|
803038022 |
0.975 — 1.000 (0.0384 — 0.0394) |
— |
— |
Snap ring (Outer-30) to ball bearing clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
|
Snap ring (Outer-30) | |
|
Part number |
Thickness mm (in) |
|
805030041 |
1.53 (0.0602) |
|
805030042 |
1.65 (0.0650) |
|
805030043 |
1.77 (0.0697) |