3.3.1.2 Manual transmission specifications 

Transmission specifications 

Applications Specification 

Gear ratio 

 

1st speed   

3.583 

2nd speed   

1.947 

3rd speed   

1.379 

4th speed   

1.03 

5th speed   

0.82 

Reverse gear 

3.363 

Main reduction ratio 

4.058 

Maximum speed 

200 

0~100km/h Maximum gradeability 

15.2 

Maximum gradeability 

40 

Gear oil capacity 

2.2L 

Lubrication oil type or model   

75W/90 GL-4 

Axial clearance for input shaft front    bearing    Mm 

-0.01～0.21 

Axial clearance for input shaft rear bearing    mm 

-0.01～0.12 

Axial clearance for input shaft 5th speed gear mm 

-0.01～0.09 

Axial clearance of output shaft front bearing mm 

-0.01～0.12 

Axial clearance of output shaft rear bearing    mm 

-0.01～0.09 

3st speed axial clearance of output shaft  mm 

-0.01～0.09 

Differential housing pinion gap    mm 

0.025～0.150 

Differential housing tightness  mm 

0.05～0.11 

Clearance between synchronizer back and gear mm 

Limit value 0.05 

 

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Lubrication Grease 

Items Specified 

grease 

Oil seal lip of drive shaft   

Conforming to hypoid gear oil SAE 75W/85W above API GL－

4 

Oil seal lip of input shaft   

Selecting gear support block   

OMEGA 85 lubricating grease 

Sealants and adhesives 

Items 

Specified sealant and adhesive 

Matching surface for clutch housing  － 

transmission housing 

Matching surface for control housing - 

transmission housing 

Matching surface for bottom cover - 

transmission housing 

Loctite 5699 or Equivalent 

Vent 

3M SUPER WEATHERSTRIP NO.8001 or equivalent class 

Bolt of differential drive gear 

3M STUD LOCKING NO.4170 or equivalent class 

Adjusting gasket and snap ring specifications 

Parts name 

Thickness mm 

Identification mark 

2.24 None 

2.31 Blue 

Snap ring (used to adjust axial clearance for input shaft 

front bearing ) 

2.38 Brown 

2.31 Black 

(2) 

2.35 None 

2.39 Blue 

2.43 Brown 

2.47 Green 

2.51 White 

2.55 Yellow 

2.59 Black 

2.63 Orange 

2.67 Blue 

Snap ring 

(used to adjust axial clearance for input shaft rear 

bearing ) 

(used to adjust axial clearance of output shaft rear 

bearing ) 

2.71 Brown 

2.82 

－

 

2.86 

－

 

2.90 

－

 

Thrust plate   

(used to adjust 5th speed axial clearance of input shaft ) 

2.94 

－

 

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2.98 

－

 

3.02 

－

 

3.06 

－

 

3.10 

－

 

1.43 Green 

(2) 

1.51 White 

(2) 

Snap ring 

(used to adjust axial clearance for output shaft front 

bearing ) 

1.59 Yellow 

(2) 

2.81 Green 

2.85 White 

2.89 Yellow 

2.93 Black 

2.97 Orange 

3.01 Red 

3.05 Peach 

Snap ring 

(used to adjust output shaft 3rd speed    axial clearance) 

3.09 Blue 

0.80 80 

0.83 83 

0.86 86 

0.89 89 

0.92 92 

0.95 95 

0.98 98 

1.01 01 

1.04 04 

1.07 07 

1.10 J 

1.13 D 

1.16 K 

1.19 L 

1.22 G 

(Used to adjust differential housing pre-tightening) 

gasket 

1.25 M 

0.75～0.82 

- 

0.83～0.92 

- 

0.93～1.00 

- 

1.01～1.08 

- 

(used to adjust differential housing backlash) shim 

1.09～1.16 

- 

 

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3.3.2 Description and operation 

3.3.2.1 Transmission system operation 

z  Notes for maintenance 

Formed in place gasket (FIPG) 

Many parts on the transmission use FIPG. When using this sealant, in order to achieve sealing purpose fully, 
please pay special attention to sealing quantity, position and surface. Too little sealant may cause leakage. 
Excessive sealant may cause sealant to be overflowed, which blocks water or oil channel or makes the channel 
narrow. Therefore, in order to prevent leakage from joint surface, correct sealing quantity and continous coating 
are absolutely necessary. 

After RTV (Room Temperature Vulcanizing) reacts with water in the atmosphere, it becomes vulcanized. 
Therefore, it is used on the flange of metal. 

Disassemble 

Without special methods, it is easy to disassemble compenents assembled by sealant. But on some occasions, it is 
necessary to use a wooden hammer or similar tools to knock on components to damage sealant on joint surface, or 
tap a smooth and thin sealant scraper into joint surface. But do not damage joint surface. 

Clean sealing surface 

Dismantle foreign matters with sealant scraper or wire brush. Confirm sealing surface is flat and smooth, without 
any oil dirt and foreign matters. Do not forget to Dismantle assembling hole and old sealant in threaded hole. 

Application essentials 

Notes when using FIPG to assemble components 

Apply sealant on specified diameter uniformly. Enclose the assembling hole. Dismantle sealant that is not 
hardened. When sealant is wet (within 15 minutes), install parts on specified position. When installing, do not 
apply sealant to undesired positions. After installation, the sealant shall be hardened enough (about 1 hour). Do 
not apply oil onto applied part or make it wet or start engine. 

Application procedures of FIPG sealant are different due to part shape. Please refer to application methods in this 
text. 

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