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Manual Transmission / Transaxle: Service Data

This document provides service specifications for manual transmissions and transaxles. It lists tolerances for various components including gear clearances, seal drive-in depths, shim thicknesses, and snap ring thicknesses. The specifications are provided for items such as the 5th gear thrust clearance, 5th gear radial clearance from different manufacturers, synchronizer ring clearance, gear diameters, seal depths, differential case shim thickness, clutch hub snap ring thickness, 4th gear thrust and radial clearances, and more. Ranges and maximum/minimum tolerances are given.

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Clodoaldo Biassio
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132 views1 page

Manual Transmission / Transaxle: Service Data

This document provides service specifications for manual transmissions and transaxles. It lists tolerances for various components including gear clearances, seal drive-in depths, shim thicknesses, and snap ring thicknesses. The specifications are provided for items such as the 5th gear thrust clearance, 5th gear radial clearance from different manufacturers, synchronizer ring clearance, gear diameters, seal depths, differential case shim thickness, clutch hub snap ring thickness, 4th gear thrust and radial clearances, and more. Ranges and maximum/minimum tolerances are given.

Uploaded by

Clodoaldo Biassio
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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03–37

SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE

MANUAL TRANSMISSION / TRANSAXLE


030QD–01

SERVICE DATA
MANUAL TRANSAXLE ASSY
5th gear thrust clearance STD: 0.10 – 0.57 mm (0.0039 – 0.0224 in.)
MAX: 0.57 mm (0.0224 in.)
5th gear radial clearance KOYO made STD: 0.015 – 0.058 mm (0.0006 – 0.0023 in.)
MAX: 0.058 mm (0.0023 in.)
NSK made STD: 0.015 – 0.056 mm (0.0006 – 0.0022 in.)
MAX: 0.056 mm (0.0022 in.)
Synchronizer ring No.3 back and 5th gear spline end clearance Min: 0.75 mm (0.0295 in.)
5th gear inner diameter STD: 29.915 – 29.931mm (1.1778 – 1.1783 in.)
MAX: 29.931mm (1.1783 in.)
Reverse idler gear sub–assy inner diameter STD: 18.040 – 18.058 mm (0.7102 – 0.7109 in.)
MAX: 18.058 mm (0.7109 in.)
Reverse idler gear shaft outer diameter STD: 17.966 – 17.984 mm (0.7073 – 0.7080 in.)
Min: 17.966 mm (0.7073 in.)
Front transaxle case oil seal drive in depth 15.6 – 16.0 mm (0.6142 – 0.6299 in.)
Input shaft front bearing drive in depth 0 – 0.3 mm (0 – 0.012 in.)
Front differential case shim thickness AA: 2.10 mm (0.0827 in.)
BB: 2.15 mm (0.0846 in.)
CC: 2.20 mm (0.0866 in.)
DD: 2.25 mm (0.0886 in.)
EE: 2.30 mm (0.0906 in.)
FF: 2.35 mm (0.0925 in.)
GG: 2.40 mm (0.0945 in.)
HH: 2.45 mm (0.0965 in.)
JJ: 2.50 mm (0.0984 in.)
KK: 2.55 mm (0.1004 in.)
LL: 2.60 mm (0.1024 in.)
MM; 2.65 mm (0.1043 in.)
NN: 2.70 mm (0.1063 in.)
PP: 2.75 mm (0.1083 in.)
QQ: 2.80 mm (0.1102 in.)
RR: 2.85 mm (0.1122 in.)
SS: 2.90 mm (0.1142 in.)
TT: 2.95 mm (0.1161 in.)
UU: 3.00 mm (0.1181 in.)
Transmission case oil seal drive in depth 9.9  0.3 mm (0.390  0.012 in.)
Transaxle case oil seal drive in depth 1.9  0.3 mm (0.075  0.012 in.)
Reverse restrict pin slotted pin drive in depth 15.5  16.5 mm (0.6102  0.6496 in.)
Transmission clutch hub No.3 snap ring thickness A: 2.25 mm (0.0886 in.)
B: 2.31 mm (0.0909 in.)
C: 2.37 mm (0.0933 in.)
D: 2.43 mm (0.0957 in.)
E: 2.49 mm (0.0980 in.)
F: 2.55 mm (0.1004 in.)
G: 2.61 mm (0.1028 in.)
INPUT SHAFT ASSY
4th gear thrust clearance STD: 0.10 – 0.55 mm (0.0039 – 0.0217 in.)
MAX: 0.55 mm (0.0217 in.)
3rd gear thrust clearance STD: 0.10 – 0.35 mm (0.0039 – 0.0138 in.)
MAX: 0.35 mm (0.0138 in.)
4th gear radial clearance KOYO made STD: 0.015 – 0.058 mm (0.0006 – 0.0023 in.)
MAX: 0.058 mm (0.0023 in.)
NSK made STD: 0.015 – 0.056 mm (0.0006 – 0.0022 in.)
MAX: 0.056 mm (0.0022 in.)

2004 COROLLA (RM1037U)

Author: Date: 141

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