MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > General Description

1. MANUAL TRANSMISSION AND DIFFERENTIAL

Model			1.5 L DOHC			2.0 L DOHC		2.5 L DOHC turbo
			FWD	AWD
Option code*¹			E2	EC, EK, K4, KS, EA, ER, EL, EP		EC, EA, EH, E2, EL, K4, KS, EK, ER, EP	KA, KC
Type			5-forward speeds with synchromesh and 1-reverse 5 × 2-forward speeds with synchromesh and 2-reverse *²
Transmission gear ratio		1st	3.454					3.166
		2nd	1.947			2.062		1.882
		3rd	1.296			1.448		1.296
		4th	0.972			1.088		0.972
		5th	0.780			0.825		0.738
		Rev.	3.333
Auxiliary transmission gear ratio*²		High	—	1.000	—	1.000	—
		Low	—	1.447	—	1.447	—
Front reduction gear	Final	Type of gear	Hypoid
		Gear ratio	4.444			4.111		4.444
Rear reduction gear	Transfer	Type of gear	—	Helical
		Gear ratio	—	1.000
	Final	Type of gear	—	Hypoid
		Gear ratio	—	4.444		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			3.3 L (3.5 US qt, 2.9 Imp qt)	3.5 L (3.7 US qt, 3.1 Imp qt) 4.0 L (4.2 US qt, 3.5 Imp qt)*²				3.5 L (3.7 US qt, 3.1 Imp qt)

*¹: For option codes, refer to the ID section.

*²: Dual-range model

2. TRANSMISSION GEAR OIL

Recommended oil:

GL-5 (75W-90) or equivalent

3. TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment

Hypoid gear backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Drive pinion shim
Part No.	Thickness mm (in)	Part No.	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 No.	Mark
4.00 — 4.13 (0.1575 — 0.1626)	32294AA041	1
3.87 — 4.00 (0.1524 — 0.1575)	32294AA051	2

Adjustment of input shaft holder

Dimension D mm (in)	Shim No.
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

Clearance between snap ring and counter washer:

0.05 — 0.35 mm (0.0020 — 0.0138 in)

Snap ring (Outer-19)
Part No.	Thickness mm (in)
031319000	1.50 (0.0591)
805019010	1.72 (0.0677)

4. DRIVE PINION ASSEMBLY

AWD model

Preload adjustment of thrust bearing

Starting torque:

0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.22 — 0.59 ft-lb)

Adjusting washer No. 1
Part No.	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 No.	Thickness mm (in)
803025059	3.850 (0.1516)
803025054	4.000 (0.1575)
803025058	4.150 (0.1634)

FWD model

1st Driven gear selection

1st driven gear
Part No.	Bushing outer diameter mm (in)
32231AA841	42.019 — 42.033 (1.6543 — 1.6548)
32231AA851	42.005 — 42.018 (1.6537 — 1.6543)
32231AA861	41.990 — 42.004 (1.6531 — 1.6537)

5. INPUT SHAFT ASSEMBLY

Ball bearing clearance adjustment snap ring (outer 28):

0 — 0.12 mm (0 — 0.0047 in)

Snap ring (Outer-28)
Part No.	Thickness mm (in)
805028050	2.48 (0.0976)
805028060	2.56 (0.1008)
805028070	2.64 (0.1039)

Ball bearing clearance adjustment snap ring (inner 68):

0 — 0.12 mm (0 — 0.0047 in)

Snap ring (Inner 68)
Part No.	Thickness mm (in)
805168020	1.84 (0.0724)
805168030	1.92 (0.0756)
806168040	2.00 (0.0787)

6. MAIN SHAFT

Clearance between snap ring (outer 25) to synchronizer hub:

0.060 — 0.100 mm (0.0024 — 0.0039 in)

Snap ring (Outer-25)
Part No.	Thickness mm (in)	Part No.	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)

7. REVERSE IDLER GEAR

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 No.	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 No.	Thickness mm (in)	Part No.	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)	—	—

8. SHIFTER FORK AND ROD

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: 3rd-4th — 5th

0.5 — 1.3 mm (0.020 — 0.051 in)

B: 1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

1st-2nd shifter fork
Part No.	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 No.	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 No.	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 No.	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).

9. TRANSFER CASE OR REAR CASE

Neutral position adjustment

Adjusting shim
Part No.	Thickness mm (in)
32190AA000	0.15 (0.0059)
32190AA010	0.30 (0.0118)

Reverse accent shaft
Part No.	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 No.	Mark	Angleθ	Remarks
32189AA001	0	28°	Arm stops closer to 5th gear.
32189AA011	1	31°	Arm stops closer to 5th gear.
33189AA021	2	34°	Arm stops in the center.
32189AA031	3	37°	Arm stops closer to reverse gear.
32189AA041	4	40°	Arm stops closer to reverse gear.

10. EXTENSION ASSEMBLY

Preload (standard protrusion) of the taper roller bearing:

0.15 — 0.20 mm (0.006 — 0.008 in)

NOTE:

Be sure that it is always within the preload.

Thrust washer (50 × 61 × t)
Part No.	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 No.	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)

11. FRONT DIFFERENTIAL

Bevel gear to pinion backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Washer (38.1 × 50 × t)
Part No.	Thickness mm (in)	Part No.	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)	—	—

12. TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

Snap ring (Outer-30)
Part No.	Thickness mm (in)
805030041	1.53 (0.0602)
805030042	1.65 (0.0650)
805030043	1.77 (0.0697)