EC65A MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA
Transmission case oil seal |
||
Installation depth |
Standard |
10.6 to 11.6 mm (0.417 to 0.457 in.) |
Transaxle case oil seal |
||
Installation depth |
Standard |
1.2 to 2.2 mm (0.0472 to 0.0866 in.) |
Shift lock solenoid |
||
Tester Connection |
Condition |
Specified Condition |
2 - 6 |
20°C (68°F) |
30 to 35 Ω |
Transmission shift main switch |
||
Tester Connection |
Shift Lever Position |
Specified Condition |
4 - 8 |
M |
Below 1 Ω |
E |
10 kΩ or higher |
|
Shift lever position sensor |
||
Tester Connection |
Shift Lever Position |
Specified Condition |
4 - 9 - 10 - 13 |
R |
Below 1 Ω |
4 - 2 - 10 - 6 |
N |
Below 1 Ω |
4 - 2 - 3 - 13 |
E, M |
Below 1 Ω |
11 - 12 |
+ |
Below 1 Ω |
11 - 5 - 12 |
M |
10 kΩ or higher |
11 - 5 |
- |
Below 1 Ω |
Standard Resistance |
||
Tester Connection |
Condition |
Specified Condition |
3 (SFTU) - 2 (ECC1) |
"+" continuously Pulled |
Below 2.5 Ω |
Released |
1 MΩ or higher |
|
2 (SFTD) - 3 (ECC) |
"-" continuously Pulled |
Below 2.5 Ω |
Released |
1 MΩ or higher |
|
2 (SFTD) - 4 (ECC1) |
"-" continuously Pulled |
Below 2.5 Ω |
Released |
1 MΩ or higher |
|
Standard Resistance |
||
Tester Connection |
Switch Condition |
Specified Condition |
1 - 2 |
Pushed |
Below 1 Ω |
Released |
10 kΩ or higher |
|
Standard Resistance |
||
Tester Connection |
Switch Condition |
Specified Condition |
1 - 2 |
Pushed |
Below 1 Ω |
Released |
10 kΩ or higher |
|
Standard Resistance |
||
Tester Connection |
Condition |
Specified Condition |
1 - 2 |
20°C (68°F) |
560 to 680 Ω |
Standard Voltage (combined dry cell battery voltage of 4.5 V) |
||
Tester Connection |
Sensor Angle |
Specified Condition |
1 (VSS1) - 2 (E2S1) |
55° |
3.6 to 4.5 V |
0° |
1.8 to 2.7 V |
|
-55° |
0.27 to 0.63 V |
|
Reference Voltage (combined dry cell battery voltage of 5.0 +/- 0.3 V) |
||
Tester Connection |
Sensor Angle |
Specified Condition |
1 (VSS1) - 2 (E2S1) |
55° |
4.0 to 5.0 V |
0° |
2.0 to 3.0 V |
|
-55° |
0.3 to 0.7 V |
|
Standard Voltage (combined dry cell battery voltage of 4.5 V) |
||
Tester Connection |
Sensor Angle |
Specified Condition |
6 (VSL1) - 5 (E2L1) |
55° |
3.6 to 4.5 V |
0° |
1.8 to 2.7 V |
|
-55° |
0.27 to 0.63 V |
|
Reference Voltage (combined dry cell battery voltage of 5.0 +/- 0.3 V) |
||
Tester Connection |
Sensor Angle |
Specified Condition |
6 (VSL1) - 5 (E2L1) |
55° |
4.0 to 5.0 V |
0° |
2.0 to 3.0 V |
|
-55° |
0.3 to 0.7 V |
|
Ring pin |
|
Protrusion height |
5.2 to 5.8 mm (0.205 to 0.228 in.) |
Reverse idler gear sub-assembly |
||
Inside diameter |
Standard Maximum |
25.056 to 25.074 mm (0.98645 to 0.98716 in.) 25.074 mm (0.98716 in.) |
Reverse idler gear shaft |
||
Outside diameter |
Standard Minimum |
24.984 to 25.000 mm (0.98362 to 0.98425 in.) 24.984 mm (0.98362 in.) |
Differential side bearing preload |
New bearing |
1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf) |
Used bearing |
0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf) |
|
Front differential case rear plate washer thickness |
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 |
2.100 mm (0.0827 in.) 2.125 mm (0.0837 in.) 2.150 mm (0.0846 in.) 2.175 mm (0.0856 in.) 2.200 mm (0.0866 in.) 2.225 mm (0.0876 in.) 2.250 mm (0.0886 in.) 2.275 mm (0.0896 in.) 2.300 mm (0.0906 in.) 2.325 mm (0.0915 in.) 2.350 mm (0.0925 in.) 2.375 mm (0.0935 in.) 2.400 mm (0.0945 in.) 2.425 mm (0.0955 in.) 2.450 mm (0.0965 in.) 2.475 mm (0.0974 in.) 2.500 mm (0.0984 in.) 2.525 mm (0.0994 in.) 2.550 mm (0.1004 in.) 2.575 mm (0.1014 in.) 2.600 mm (0.1024 in.) 2.625 mm (0.1033 in.) 2.650 mm (0.1043 in.) 2.675 mm (0.1053 in.) 2.700 mm (0.1063 in.) 2.725 mm (0.1073 in.) 2.750 mm (0.1083 in.) 2.775 mm (0.1093 in.) 2.800 mm (0.1102 in.) 2.825 mm (0.1112 in.) 2.850 mm (0.1122 in.) |
Output shaft bearing preload |
New bearing |
4.0 to 6.9 N*m (41 to 70 kgf*cm, 35 to 61 in.*lbf) |
Used bearing |
2.6 to 4.4 N*m (27 to 45 kgf*cm, 23 to 39 in.*lbf) |
|
Rear output shaft bearing shim thickness |
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 |
1.750 mm (0.0689 in.) 1.775 mm (0.0699 in.) 1.800 mm (0.0709 in.) 1.825 mm (0.0719 in.) 1.850 mm (0.0728 in.) 1.875 mm (0.0738 in.) 1.900 mm (0.0748 in.) 1.925 mm (0.0758 in.) 1.950 mm (0.0768 in.) 1.975 mm (0.0778 in.) 2.000 mm (0.0787 in.) 2.025 mm (0.0797 in.) 2.050 mm (0.0807 in.) 2.075 mm (0.0817 in.) 2.100 mm (0.0827 in.) 2.125 mm (0.0837 in.) 2.150 mm (0.0846 in.) 2.175 mm (0.0856 in.) 2.200 mm (0.0866 in.) 2.225 mm (0.0876 in.) 2.250 mm (0.0886 in.) 2.275 mm (0.0896 in.) 2.300 mm (0.0906 in.) 2.325 mm (0.0915 in.) 2.350 mm (0.0925 in.) 2.375 mm (0.0935 in.) 2.400 mm (0.0945 in.) 2.425 mm (0.0955 in.) 2.450 mm (0.0965 in.) 2.475 mm (0.0974 in.) 2.500 mm (0.0984 in.) 2.525 mm (0.0994 in.) 2.550 mm (0.1004 in.) 2.575 mm (0.1014 in.) 2.600 mm (0.1024 in.) 2.625 mm (0.1033 in.) 2.650 mm (0.1043 in.) 2.675 mm (0.1053 in.) 2.700 mm (0.1063 in.) 2.725 mm (0.1073 in.) 2.750 mm (0.1083 in.) 2.775 mm (0.1093 in.) 2.800 mm (0.1102 in.) |
Transmission case gasket |
||
Drive in depth |
0 to 1.0 mm (0 to 0.0394 in.) |
|
Straight pin |
||
Protrusion height |
8.5 to 9.5 mm (0.335 to 0.374 in.) |
|
Front transaxle case oil seal |
||
Drive in depth |
0.9 to 1.9 mm (0.0354 to 0.0748 in.) |
|
Rear input shaft bearing shim thickness |
08 09 10 11 12 13 14 15 16 17 18 19 |
1.30 mm (0.0512 in.) 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) |
Shift and select lever shaft head |
||
Drive in depth |
Standard |
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Inner select lever |
||
Drive in depth |
Standard |
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Inner No. 1 shift lever |
||
Drive in depth |
Standard |
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Front inner shift lever |
||
Drive in depth |
Standard |
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Inner No. 2 shift lever |
||
Drive in depth |
Standard |
0 to 0.6 mm (0 to 0.0236 in.) |
Ring pin |
||
Protrusion height |
5.2 to 5.8 mm (0.205 to 0.228 in.) |
|
Thrust clearance |
Standard 3rd 4th 5th 6th |
0.15 to 0.43 mm (0.00591 to 0.0169 in.) 0.15 to 0.56 mm (0.00591 to 0.0220 in.) 0.15 to 0.43 mm (0.00591 to 0.0169 in.) 0.15 to 0.43 mm (0.00591 to 0.0169 in.) |
Maximum 3rd 4th 5th 6th |
0.43 mm (0.0169 in.) 0.56 mm (0.0220 in.) 0.43 mm (0.0169 in.) 0.43 mm (0.0169 in.) |
|
Radial clearance |
Standard 3rd 4th 5th 6th |
0.009 to 0.050 mm (0.000354 to 0.0197 in.) 0.009 to 0.050 mm (0.000354 to 0.0197 in.) 0.009 to 0.045 mm (0.000354 to 0.00177 in.) 0.009 to 0.045 mm (0.000354 to 0.00177 in.) |
Maximum 3rd 4th 5th 6th |
0.050 mm (0.00197 in.) 0.050 mm (0.00197 in.) 0.045 mm (0.00177 in.) 0.045 mm (0.00177 in.) |
|
Input shaft |
||
Runout |
Maximum |
0.015 mm (0.000591 in.) |
Outer diameter |
Standard Location A Location B Location C Location D |
25.002 to 25.017 mm (0.98432 to 0.98491 in.) 37.485 to 37.500 mm (1.47578 to 1.47637 in.) 31.690 to 31.700 mm (1.24763 to 1.24802 in.) 27.990 to 28.000 mm (1.10196 to 1.10236 in.) |
Minimum Location A Location B Location C Location D |
25.002 mm (0.98432 in.) 37.485 mm (1.47578 in.) 31.690 mm (1.24763 in.) 27.990 mm (1.10196 in.) |
|
Gear bearing race |
||
Outer diameter |
Standard 5th 6th |
37.49 to 37.50 mm (1.47598 to 1.47637 in.) 35.09 to 35.10 mm (1.38149 to 1.38188 in.) |
Minimum 5th 6th |
37.49 mm (1.47598 in.) 35.09 mm (1.38149 in.) |
|
Inner diameter |
Standard 5th 6th |
31.705 to 31.720 mm (1.24822 to 1.24881 in.) 28.005 to 28.020 mm (1.10255 to 1.10314 in.) |
Maximum 5th 6th |
31.720 mm (1.24881 in.) 28.020 mm (1.10314 in.) |
|
Gear |
||
Inside diameter |
Standard 3rd 4th 5th 6th |
42.509 to 42.525 mm (1.67357 to 1.67420 in.) 42.509 to 42.525 mm (1.67357 to 1.67420 in.) 42.509 to 42.525 mm (1.67357 to 1.67420 in.) 40.109 to 40.125 mm (1.57909 to 1.57972 in.) |
Maximum 3rd 4th 5th 6th |
42.525 mm (1.67420 in.) 42.525 mm (1.67420 in.) 42.525 mm (1.67420 in.) 40.125 mm (1.57972 in.) |
|
Synchronizer ring |
||
Clearance |
Standard No. 3 No. 5 |
0.78 to 1.58 mm (0.0307 to 0.0622 in.) 0.73 to 1.53 mm (0.0287 to 0.0602 in.) |
Minimum No. 3 No. 5 |
0.78 mm (0.0307 in.) 0.73 mm (0.0287 in.) |
|
Outer 2nd synchronizer ring |
||
Clearance |
Standard |
0.78 to 1.58 mm (0.0307 to 0.0622 in.) |
Minimum |
0.78 mm (0.0307 in.) |
|
Transmission hub sleeve |
||
Clearance |
Standard No. 2 No. 3 |
0.1 to 0.5 mm (0.00394 to 0.0197 in.) 0.1 to 0.5 mm (0.00394 to 0.0197 in.) |
No. 2 clutch hub setting shaft snap |
||
Clearance |
Standard |
0.1 mm (0.00394 in.) or less |
Thickness |
0 1 2 3 4 5 6 7 |
2.27 mm (0.0894 in.) 2.32 mm (0.0913 in.) 2.37 mm (0.0933 in.) 2.42 mm (0.0953 in.) 2.47 mm (0.0972 in.) 2.52 mm (0.0992 in.) 2.57 mm (0.1012 in.) 2.62 mm (0.1031 in.) |
Rear input shaft bearing shaft snap ring |
||
Clearance |
Standard |
0.1 mm (0.00394 in.) or less |
Thickness |
A B C D E F G H J K L M N P |
1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) |
Thrust clearance |
Standard 1st 2nd |
0.20 to 0.38 mm (0.00787 to 0.0150 in.) 0.15 to 0.33 mm (0.00591 to 0.0130 in.) |
Maximum 1st 2nd |
0.38 mm (0.0150 in.) 0.33 mm (0.0130 in.) |
|
Radial clearance |
Standard 1st 2nd |
0.009 to 0.047 mm (0.000354 to 0.00185 in.) 0.009 to 0.047 mm (0.000354 to 0.00185 in.) |
Maximum 1st 2nd |
0.047 mm (0.00185 in.) 0.047 mm (0.00185 in.) |
|
Output shaft |
||
Runout |
Maximum |
0.015 mm (0.000591 in.) |
Outer diameter |
Standard Location A Location B Location C Location D |
30.002 to 32.017 mm (1.1812 to 1.2605 in.) 37.990 to 38.000 mm (1.49566 to 1.49606 in.) 40.790 to 40.800 mm (1.60590 to 1.60629 in.) 28.002 to 28.017 mm (1.10243 to 1.10302 in.) |
Minimum Location A Location B Location C Location D |
30.002 mm (1.1812 in.) 37.990 mm (1.49566 in.) 40.790 mm (1.60590 in.) 28.002 mm (1.10243 in.) |
|
Gear |
||
Inside diameter |
Standard 1st 2nd |
52.909 to 52.925 mm (2.08302 to 2.08365 in.) 52.909 to 52.925 mm (2.08302 to 2.08365 in.) |
Maximum 1st 2nd |
52.925 mm (2.08365 in.) 52.925 mm (2.08365 in.) |
|
1st gear bushing |
||
Outer diameter |
Standard |
47.89 to 47.90 mm (1.88542 to 1.88582 in.) |
Minimum |
47.89 mm (1.88542 in.) |
|
Inside diameter |
Standard |
40.805 to 40.820 mm (1.60649 to 1.60708 in.) |
Maximum |
40.820 mm (1.60708 in.) |
|
Inner 2nd gear bearing race |
||
Outer diameter |
Standard |
47.89 to 47.90 mm (1.88542 to 1.88582 in.) |
Minimum |
47.89 mm (1.88542 in.) |
|
Inside diameter |
Standard |
38.005 to 38.020 mm (1.49625 to 1.49684 in.) |
Maximum |
38.020 mm (1.49684 in.) |
|
No. 1 synchronizer ring set |
||
Clearance |
Standard 1st gear side 2nd gear side |
0.915 to 1.855 mm (0.03602 to 0.07303 in.) 0.92 to 1.86 mm (0.0362 to 0.0732 in.) |
Minimum 1st gear side 2nd gear side |
0.915 mm (0.03602 in.) 0.92 mm (0.0362 in.) |
|
Reverse gear |
||
Clearance |
Standard |
0.1 to 0.5 mm (0.00394 to 0.0197 in.) |
Standard Resistance |
||
Tester Connection |
Condition |
Specified Condition |
11 (MSW1) - 8 (MSW2) |
Pushed |
Below 1 Ω |
Not pressed |
10 kΩ or higher |
|
Front differential side gear backlash |
Standard |
0.05 to 0.20 mm (0.00197 to 0.00787 in.) |
Thrust washer thickness |
14 02 15 03 16 04 |
0.95 (0.0374) 1.00 (0.0394) 1.05 (0.0413) 1.10 (0.0433) 1.15 (0.0453) 1.20 (0.0472) |
Front differential pinion thrust washer |
||
Thickness |
Minimum |
0.92 mm (0.0362 in.) |
Front No. 1 differential pinion shaft |
||
Outer diameter |
Minimum |
16.982 mm (0.669 in.) |
Capacity |
Classification |
2.4 liters (2.5 US qts, 2.1 Imp. qts) |
Toyota Genuine Manual Transmission Gear Oil "LV GL-4 and SAE 75W" or "API GL-4 and SAE 75W" |