Manual Transmission And Differential - Honda Civic 2002-2003 Service Manual

Standards and Service Limits
Manual Transmission and Differential (cont'd)
Item
Measurement
Qualification
Standard or New Service Limit
Mainshaft 4th I.D. 32.00~32.01 mm
(1.2598--1.2602
in.) 32.02 mm (1.261 in.)
and 5th gears
D.D. 38.989-39.000 mm (1.5350 1.5354
in.)
38.94 mm (1.533 in.)
distance collar
Length A
51.95-52.05 mm (2.045-2.049 in.)
B 24.03-24.08 mm 10.946-0.947 in.)
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MBS distance I.D. 28.00-28.01 mm (1.102-1.103 in.) 28.02 mm (1.103 in.)
collar Length 23.95-24.05 mm (0.943-0.947 in.)
Reverse idler
I.D. 20.016-20.043
mm
(0.7880-0.7891
in.) 20.90 mm {O.832 in.}
gear Gear-to-reverse gear shaft clearance 0.036 - 0.084
mm
(0.0014
0.0033
in.)
0.16
mm
(D.OOS
in.)
Synchro ring Ring-ta-gear clearance Ring pushed 0.70 - 1.49 mm (0.028-0.059 in.) 0.4 mm (0.016 in.)
against gear
Triple cone
Outer synchro ring-to-synchro cane
Ring pushed 0.70 - 1.19 mm
W.028
-0.047 in.) 0.3 mm (0.012 in.)
synchro
clearance against gear
Synchra cone-to-gear clearance Ring pushed '0.50-1.04 mm (0.020-0.041 in.) 0.3 mm W.012 in.)
against gear
I
Outer synchra ring-ta-gear cone Ring pushed 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.)
clearance against gear
Shift fork Finger thickness 7.4-7.6 mm
W.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
Finger
thin~_~_~~s
13.4-13.7 mm W.527-0.539 in.)
_.
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fork Fark-ta-reverse idler gear clearance 0.20-0.59 mm (0.007-0.024 in.)
1.3 mm (0.051 in.)
Shift arm J.D. 13.973-14.000 mm W.5501-0.5512 in.)
Shift fork diameter at contact area 16.9 -17.0mm(0.665
0.669 in.)
Shift arm-to-shift lever clearance , 0.2 0.5 mm (0.008- 0.020 in.) 0.62 mm (0.024 in.)
l
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Select lever Finger width 14.85-14.95 mm (0.585-0.589 in.)
Shift lever Shaft-ta-select lever clearance 0.05-0.25 mm (0.002-0.010 in.) 0.50 mm (0.020 in.)
Groave (to select lever) 15.00- -15.10 mm W.591---0.594 in.)
Shaft-ta-shift arm clearance 0.013-0.07 mm (0.0005-0.003 in.) 0.1 mm (0.004 in.)
MIT Pinion shaft contact area I.D. 18.010-18.028 mm (0.7091-0.7098 in.)
differential Carrier-to-pinion shaft clearance 0.027-0.057 mm (0.0011-0.0022 in.)
0.1 mm (0.004 in.)
carrier Driveshaft contact area I.D. 28.025-28.045 mm (1.1033- 1.1041 in.)
MIT
Backlash
0.05-0.15 mm(O.002-0.006 in.)
differential I.D. 18.042-18.066 mm (0.7103- 0.7113 in.)
pinion gear Pinion gear-to-pinion shaft clearance
0.059-0.095 mm (0.0023-0.0037 in.) 0.15 mm W.OOG in.)
80mmshim 80 mm shim-to-bearing outer race 0-0.10 mm (0 0.0039 in.) Adjust
clearance in transmission housing
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2-8