Page 208 of 230
CLUTCH
CLUTCH DISC
CLUTCH PEDAL
Engine type I RB20DE I RB25DE I RB25DET
Engine
type
CLUTCH COVER
RB20DE RB25DE
Size mm
Wear
limit (depth to rivet head) mm
Runout limit / diameter at measurement mm
Maximum backlash
at spline mm
Pedal
height mm
Pedal height at clutch released mm
Pedal free play (clevis pin clearance) mm
RB25DET
225 dia. I 240 dia. I 250 dia.
0.3
Engine type
Size mm
TIGHTENING TORQUE
Unit: N-m (ka-m)
172 - 182
Less than 0.7
/ 21 5 dia.
0.9
Diaphragm spring lever height mm
Variation in diaphragm spring lever height mm
Clutch cover fixing bolt More
than 82
RB20DE
225 dia.
Clutch master cylinder fixing bolt
I 7.9 - 10 (0.8 - 1 .I)
Less
than 1.0
/ 230 dia.
33.0
- 35.0
Less than 0.7
9 - 16 (1.0 - 3.0)
More
than 81
Less than 0.7
/ 240 dia.
RB25DE
240 dia. More
than 85
1
.O
RB25DET
250 dia.
37.5
- 39.5
Less than 0.5 48.2
- 50.2
Less than 0.6
Page 209 of 230

MANUAL TRANSMISSION
BACKLASH ADJUSTING SHIMS
Measurement height
mm
--
Items
Main drive gear
1st gear
2nd gear
3rd gear Thickness
mm Standard mm
0.05 - 0.10
0.05
- 0.20
0.05
- 0.20
0.05
- 0.20
Selective parts Parts number
Counter shaft
front bearing
4th gear I -
5th gear 1 0.05 - 0.20 Ail
BAULK RlNG CLEARANCE Reverse idler gear 1 0.05 - 0.20
END PLAY Measurement
position
2nd and 3rd
Inner baulk ring clearance 'an
1 st gear 1 0.31 - 0.41
Items
2nd gear
1 0.11-0.21
Standard
mm
3rd gear 1 0.11 - 0.21
Outer
baulk ring
lnn'er baulk ring
7 4th gear 5th gear
Reverse idler gear
Counter gear Main drive gear end play
Mainshaft high-synchro side
Rear end of mainshaft end bearing
SNAP RlNG
- -
0.24 - 0.41
0.05
- 0.50
0
- 0.16
0
- 0.13
0 - 0.18
0
- 0.14
4th and 5th ( 1.20 - 1.60 1 Less than 0.8
Selective parts
Thickness
mm I Parts number - -- Reverse gear 1 1.10 - 1.55 1 Less than 0.7
Main drive gear
TIGHTENING TORQUE
Unit: N.m (kg-rn)
Counter drive gear
I
TIM side to 40 - 49
Transmission to engine mounting bolt Engine side to 30
- 39
TIM side (3.0 - 4.0) I High-synchro side 32263 V5200 1 32263
"5201
Rear end of shaft I I
Mainshaft 1.1
32228 20 1 00
Page 220 of 230

FRONT FINAL DRIVE
DRIVE GEAR RUNOUT
Type F160
Thrust washer for adjustment of clearance at reverse side of side gear
Amount of runout at reverse side of drive gear mm
Less than 0.05
ADJUSTMENT OF SIDE GEAR CLEARANCE
Thickness mm 1 Parts number 1 Thickness mm 1 Parts number 1 Thickness mm 1 Parts number 1 Thickness rnm 1 Parts number
TY pe
F160
ADJUSTMENT OF DRIVE PINION HEIGHT
Clearance at reverse side of side gear mm
Less than
0.1 5, and side gear must be rotated freely.
Adjusting washer for adjustment of drive pinion height
Thickness mrn 1 Parts number 1 Thickness mm 1 Parts number 1 Thickness mm Parts
number
Adjusting washer for adjustment of drive pinion pre-load
ADJUSTMENT
OF DRIVE PINION
PRE-LOAD
- - - pppp - --
Thickness mmr Parts number [~hickness mm 1 Parts numbaJ~hickness mm Thickness mm
Type
Parts
number Parts
number
Drive pinion pre-load N-m (kg-m)
Thickness mrn
2.55
2.57
2.59
-- -
Parts number
Adjusting spacer for adjustment of drive pinion pre-load
Thickness mm I Parts number I Thickness rnrn I Parts number I Thickness mm 1 Parts number
Page 222 of 230

REAR FINAL DRIVE
DRIVE GEAR RUNOUT
Type I Amount of runout at reverse side of drive gear mm
R200 (Strengthened), R200V (Strengthened) I Less than 0.05
ADJUSTMENT OF SIDE GEAR CLEARANCE
Thrust washer for adjustment of clearance at reverse side of
side
Type
R200 (Strengthened)
R200V (Strengthened)
Thrust washer Clearance
at reverse side of side gear
mm
Less than 0.15, and side gear must be rotated freely.
0.03 - 0.09
- -- -
Thickness mm
ADJUSTMENT OF DRIVE PINION HEIGHT
R200 (Strengthened, 2-pinion) R200 (Strengthened, 4-pinion)
Adjusting washer for adjustment of drive pinion height
-, Parts number Thickness mm
38424 N3110
0.75 - 0.80
38424
N3111
0.80
- 0.85
38424
N3112
0.85
- 0.90
gear
Parts number
38424 1 OVOO
38424 1 OVO1
38424 1
OV02 R200V
(Strengthened)
Thickness mm
0.80
0.83
0.86
0.89 0.92
0.95
0.98
1 .O1
1.04
1.07 1.10
1.13
1.16
1.19
1.22
1.25
1.28 1.31
1.34
1.37
1-40
1.43 1.46 1.49
Parts number
-- -
Type
Adjusting
washer R200
(Strengthened), R200V (Strengthened)
Thickness mrn
3.54
3.57
3.60 3.63
3.66
Parts number
381 54
P6027
381 54
P6028
381 54
P6029
38 1 54
P6030
38
1 54 P603 1
Thickness mm
3.09
3.12
3.1 5
3.18
3.21 Parts number
381
54 P6032
38 1
54
P6033
381
54 P6034
38 1 54 P6035
381 54 P6036
Parts number
381 54
P6017
38154
P6018
38154
P6019
38
154
P6020
38154
P6021
Thickness
mrn
3.39
3.42
3.45
3.48
3.51
Thickness
mm
3.24
3.27
3.30
3.33
3.36 Parts
number
381 54
P6022
381 54
P6023
381 54
P6024
381 54
P6025
38154
P6026
Page 228 of 230

BRAKE
BRAKING FORCE
More than 10% of axle
weight
REAR DlSC BRAKE
Total braking force of rear wheels
Variation between right and left of
each wheel Brake
type
Less than 8% of axle weight ADllVC
9.3
Brake
pad
Disc rotor
Total
braking force OPZ11V
11.5
Standard
thickness (New) mm
Wear limit of thickness mm
Standard thickness (New) mm
Wear limit of thickness mm
Runout limit mm
More than 50%
of vehicle
weight at inspected
Note: The braking force when both front wheels are locked up can be considered to meet the total braking force.
2.0
16
14
BRAKE PEDAL
18
16
PARKING BRAKE
Free play (at pedal top surface)
mm I 3 - 11 Less than
0.07 Type DS17HD I
Brake
lining
Depressed pedal height under force
of 490 N (50 kg)
(from dash panel top surface)
mm
Brake
pedal height
(from dash panel top surface)
mm
Standard inner diameter
I (New) mm I
Standard thickness (New) mrn
Wear limit of thickness
mm M/T: 163 - 173 IVT: 170 - 180
172 dia. 3.0 1.5
M/T: More
than 85 A. More than 90 . . Drum I
I
Wear limit of inner diameter
mm I 173 dia.
Clearance between the edge of stop
lamp switch screw and pedal stopper
mm Operating
stroke
[under force of 196 N (20
kg)] 5 - 7 notches
CHECK VALVE I
I
Maximum stroke
19 notches
Number of notches when brake warning
lamp turns on
TIGHTENING TORQUE
Unit: N.m (kg-m)
Within 1 notch
Vacuum leakage
[at
vacuum Of 66'7 kPa (-500 mmHg)]
BRAKE BOOSTER
Within 1.3 kPa (10 mmHg) of
vacuum for 15 seconds
Master cylinder fixing nut
I 12 - 14 (1.2 - 1.5)
Vacuum leakage
[at vacuum of 66.7
kPa
(-500
mmHg)l
Within 3.3
kPa
(25
mmHg)
of
vacuum for 15 seconds Front
caliper mounting bolt
Brake tube flare nut -- - 152 - 154 (15.5 - 15.8)
15
- 17 (1.5 - 1.8)
FRONT DlSC BRAKE
Input rod standard length at installed
mm
Brake type
I AD25VB I CUSVD [OPZ~~VC
140
Standard thickness
Wear limit of
thickness
Standard thickness
mm
1 22 1 26 1 30
Disc rotor Wear limit of
thickness
Runout
limit Less than 0.07