EA65 MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

Differential Oil Seal
Transaxle case oil seal
Installation depth Standard -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Front transaxle case oil seal
Installation depth Standard -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Back-up Light Switch

Resistance

1 - 2

 Pushed Below 1 Ω
Released 10 kΩ or higher
Park/Neutral Position Switch

Resistance

1 - 2

 Pushed Below 1 Ω
Released 10 kΩ or higher
Manual Transaxle Unit
Reverse idler gear thrust clearance Standard 0.40 to 1.05 mm (0.00158 to 0.0413 in.)
Maximum 1.05 mm (0.0413 in.)
Reverse idler gear radial clearance Standard 0.015 to 0.048 mm (0.000591 to 0.00188 in.)
Maximum 0.048 mm (0.00188 in.)
Shift fork shaft bearing standard depth 0 to 0.5 mm (0 to 0.0197 in.)
Transaxle case oil seal standard depth 4.4 to 5.0 mm (0.174 to 0.196 in.)
Shift and select lever shaft needle roller bearing clearance 177.8 to 178.7 mm (7.00 to 7.03 in.)
Shift fork shaft bearing Clearance A 168.2 to 169.3 mm (6.63 to 6.66 in.)
Clearance B 162.2 to 163.3 mm (6.39 to 6.42 in.)
Transmission case oil seal depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Transaxle case oil seal depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Differential side bearing preload New bearing preload 1.00 to 2.49 N*m (10.2 to 25.3 kgf*cm, 8.85 to 22.03 in.*lbf)
Front differential case rear shim thickness 0 1.99 to 2.01 mm (0.0783 to 0.0791 in.)
1 2.04 to 2.06 mm (0.0803 to 0.0811 in.)
2 2.09 to 2.11 mm (0.0823 to 0.0831 in.)
3 2.14 to 2.16 mm (0.0843 to 0.0850 in.)
4 2.19 to 2.21 mm (0.0862 to 0.0870 in.)
5 2.24 to 2.26 mm (0.0882 to 0.0890 in.)
6 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
7 2.34 to 2.36 mm (0.0921 to 0.0929 in.)
8 2.39 to 2.41 mm (0.0941 to 0.0949 in.)
9 2.44 to 2.46 mm (0.0961 to 0.0969 in.)
A 2.49 to 2.51 mm (0.0981 to 0.0988 in.)
B 2.54 to 2.56 mm (0.1000 to 0.1007 in.)
C 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
D 2.64 to 2.66 mm (0.1040 to 0.1047 in.)
E 2.69 to 2.71 mm (0.1060 to 0.1066 in.)
F 2.74 to 2.76 mm (0.1079 to 0.1086 in.)
G 2.79 to 2.81 mm (0.1099 to 0.1106 in.)
H 2.84 to 2.86 mm (0.1119 to 0.1125 in.)

No. 2 output shaft rear bearing preload

New bearing preload

 w/o DPF 3.89 to 5.51 N*m (40 to 56 kgf*cm, 35 to 48 in.*lbf)
w/ DPF 3.66 to 5.18 N*m (38 to 52 kgf*cm, 33 to 45 in.*lbf)
No. 2 output shaft rear bearing shim thickness A 1.79 to 1.81 mm (0.0705 to 0.0713 in.)
B 1.84 to 1.86 mm (0.0724 to 0.0732 in.)
C 1.89 to 1.91 mm (0.0744 to 0.0752 in.)
D 1.94 to 1.96 mm (0.0764 to 0.0772 in.)
E 1.99 to 2.01 mm (0.0783 to 0.0791 in.)
F 2.04 to 2.06 mm (0.0803 to 0.0811 in.)
G 2.09 to 2.11 mm (0.0823 to 0.0831 in.)
H 2.14 to 2.16 mm (0.0843 to 0.0850 in.)
J 2.19 to 2.21 mm (0.0862 to 0.0870 in.)
K 2.24 to 2.26 mm (0.0882 to 0.0890 in.)
L 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
M 2.34 to 2.36 mm (0.0921 to 0.0929 in.)
N 2.39 to 2.41 mm (0.0941 to 0.0949 in.)
P 2.44 to 2.46 mm (0.0961 to 0.0969 in.)
Q 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
R 2.54 to 2.56 mm (0.1000 to 0.1007 in.)
S 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
T 2.64 to 2.66 mm (0.1040 to 0.1047 in.)
No. 5 gear shift fork shaft pin standard depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
3rd and 4th shift fork shaft pin standard depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Input Shaft
Input shaft runout Maximum 0.03 mm (0.00118 in.)
Input shaft outer diameter Measured Part A 30.008 to 30.020 mm (1.1815 to 1.1818 in.)
Measured Part B 32.002 to 32.018 mm (1.2600 to 1.2604 in.)
Input shaft rear bearing shaft snap ring thrust clearance 0.1 mm (0.00394 in.) or less
Input shaft rear bearing shaft snap ring thickness A 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
B 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
C 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
D 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
E 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
3 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
4 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
5 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
6 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
F 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
G 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
H 2.50 to 2.55 mm (0.0984 to 0.100 in.)
No. 1 Output Shaft
No. 1 output shaft runout Maximum 0.03 mm (0.00118 in.)
No. 1 Output shaft Standard Outer Diameter

Measured Part A

Measured Part B

Measured Part C

Measured Part D

Measured Part E

Measured Part F

32.002 to 32.018 mm (1.2600 to 1.2605 in.)

35.984 to 36.000 mm (1.4167 to 1.4173 in.)

41.984 to 42.000 mm (1.6530 to 1.6535 in.)

41.989 to 42.000 mm (1.6532 to 1.6535 in.)

46.984 to 47.000 mm (1.8498 to 1.8503 in.)

36.002 to 36.018 mm (1.4174 to 1.4180 in.)
1st driven gear thrust clearance Standard 0.10 to 0.35 mm (0.00394 to 0.0137 in.)
Maximum 0.35 mm (0.0137 in.)
2nd driven gear thrust clearance Standard 0.11 to 0.46 mm (0.00434 to 0.0181 in.)
Maximum 0.46 mm (0.0181 in.)
3rd driven gear thrust clearance Standard 0.11 to 0.54 mm (0.00434 to 0.0212 in.)
Maximum 0.54 mm (0.0212 in.)
4th driven gear thrust clearance Standard 0.10 to 0.65 mm (0.00394 to 0.0255 in.)
Maximum 0.65 mm (0.0255 in.)
1st driven gear radial clearance Standard 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
Maximum 0.068 mm (0.00267 in.)
2nd driven gear radial clearance Standard 0.015 to 0.048 mm (0.000591 to 0.00188 in.)
Maximum 0.048 mm (0.00188 in.)
3rd driven gear radial clearance Standard 0.015 to 0.066 mm (0.000591 to 0.00259 in.)
Maximum 0.066 mm (0.00259 in.)
4th driven gear radial clearance Standard 0.015 to 0.066 mm (0.000591 to 0.00259 in.)
Maximum 0.066 mm (0.00259 in.)
1st and 2nd shift fork shaft outer diameter Standard 13.982 to 14.000 mm (0.5505 to 0.5511 in.)
Minimum 13.982 mm (0.5505 in.)
3rd and 4th shift fork shaft outer diameter Standard 13.982 to 14.000 mm (0.5505 to 0.5511 in.)
Minimum 13.982 mm (0.5505 in.)
5th and 6th shift fork shaft outer diameter Standard 13.982 to 14.000 mm (0.5505 to 0.5511 in.)
Minimum 13.982 mm (0.5505 in.)
Reverse shift fork shaft outer diameter Standard 13.982 to 14.000 mm (0.5505 to 0.5511 in.)
Minimum 13.982 mm (0.5505 in.)
No. 5 gear shift fork shaft outer diameter Standard 15.966 to 15.984 mm (0.6286 to 0.6292 in.)
Minimum 15.966 mm (0.6286 in.)
No. 1 gear shift fork inside diameter and thickness Thickness 9.50 to 9.80 mm (0.375 to 0.385 in.)
Inside diameter 14.010 to 14.043 mm (0.5516 to 0.5528 in.)
No. 2 gear shift fork inside diameter and thickness Thickness A 9.50 to 9.80 mm (0.375 to 0.385 in.)
Inside diameter B 14.010 to 14.043 mm (0.5516 to 0.5528 in.)
Inside diameter C 14.70 to 15.30 mm (0.579 to 0.602 in.)
No. 3 gear shift fork inside diameter and thickness Thickness 9.50 to 9.80 mm (0.375 to 0.385 in.)
Inside diameter 14.010 to 14.043 mm (0.5516 to 0.5528 in.)
Reverse shaft fork inside diameter and thickness Thickness A 4.40 to 4.56 mm (0.174 to 0.179 in.)
Inside diameter B 14.010 to 14.043 mm (0.5516 to 0.5528 in.)
Inside diameter C 14.70 to 15.30 mm (0.579 to 0.602 in.)
No. 2 gear shift head inside diameter Standard 13.994 to 14.054 mm (0.551 to 0.553 in.)
Maximum 14.054 mm (0.553 in.)
No. 3 gear shift head inside diameter Standard A 15.994 to 16.054 mm (0.630 to 0.632 in.)
Standard B 14.20 to 14.25 mm (0.560 to 0.561 in.)
Maximum A 16.054 mm (0.632 in.)
Maximum B 14.25 mm (0.561 in.)
1st driven gear inside diameter Standard 53.015 to 53.040 mm (2.0872 to 2.0881 in.)
Maximum 53.040 mm (2.0881 in.)
2nd driven gear inside diameter Standard 56.015 to 56.030 mm (2.2054 to 2.2059 in.)
Maximum 56.030 mm (2.2059 in.)
3rd driven gear inside diameter Standard 42.015 to 42.040 mm (1.6542 to 1.6551 in.)
Maximum 42.040 mm (1.6551 in.)
4th driven gear inside diameter Standard 48.015 to 48.040 mm (1.8904 to 1.8913 in.)
Maximum 48.040 mm (1.8913 in.)
1st driven gear synchronizer ring clearance Standard 0.98 to 1.82 mm (0.0386 to 0.0716 in.)
Minimum 0.98 mm (0.0386 in.)
2nd driven gear synchronizer ring clearance Standard 1.08 to 1.92 mm (0.0426 to 0.0755 in.)
Minimum 1.08 mm (0.0426 in.)
3rd driven gear synchronizer ring clearance Standard 1.00 to 2.00 mm (0.0394 to 0.0787 in.)
Minimum 1.00 mm (0.0394 in.)
4th driven gear synchronizer ring clearance Standard 0.92 to 1.88 mm (0.0363 to 0.0740 in.)
Minimum 0.92 mm (0.0363 in.)
No. 1 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0196 in.)
No. 2 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0196 in.)
No. 2 Output Shaft
No. 2 output shaft runout Maximum 0.03 mm (0.00118 in.)
No. 2 output shaft outer diameter Measured Part A 32.002 to 32.018 mm (1.2600 to 1.2605 in.)
Measured Part B 35.984 to 36.000 mm (1.4167 to 1.4173 in.)
Measured Part C 41.984 to 42.000 mm (1.6530 to 1.6535 in.)
Measured Part D 46.984 to 47.000 mm (1.8498 to 1.8503 in.)
Measured Part E 35.002 to 35.018 mm (1.3781 to 1.3786 in.)
5th driven gear thrust clearance Standard 0.10 to 0.55 mm (0.00394 to 0.0216 in.)
Maximum 0.55 mm (0.0216 in.)
6th driven gear thrust clearance Standard 0.10 to 0.55 mm (0.00394 to 0.0216 in.)
Maximum 0.55 mm (0.0216 in.)
Reverse driven gear thrust clearance Standard 0.11 to 0.34 mm (0.00434 to 0.0133 in.)
Maximum 0.34 mm (0.0133 in.)
5th driven gear radial clearance Standard 0.015 to 0.066 mm (0.000591 to 0.00259 in.)
Maximum 0.066 mm (0.00259 in.)
6th driven gear radial clearance Standard 0.015 to 0.066 mm (0.000591 to 0.00259 in.)
Maximum 0.066 mm (0.00259 in.)
Reverse driven gear radial clearance Standard 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
Maximum 0.068 mm (0.00267 in.)
5th driven gear inside diameter Standard 48.015 to 48.040 mm (1.890 to 1.891 in.)
Maximum 48.040 mm (1.891 in.)
6th driven gear inside diameter Standard 42.015 to 42.040 mm (1.654 to 1.655 in.)
Maximum 42.040 mm (1.655 in.)
Reverse driven gear inside diameter Standard 53.015 to 53.040 mm (2.0873 to 2.0881 in.)
Maximum 53.040 mm (2.0881 in.)
5th driven gear synchronizer ring clearance Standard 0.80 to 1.60 mm (0.0315 to 0.0629 in.)
Minimum 0.80 mm (0.0315 in.)
6th driven gear synchronizer ring clearance Standard 0.80 to 1.60 mm (0.0315 to 0.0629 in.)
Minimum 0.80 mm (0.0315 in.)
Reverse driven gear synchronizer ring clearance Standard 0.68 to 1.32 mm (0.0268 to 0.0519 in.)
Minimum 0.68 mm (0.0268 in.)
No. 3 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0196 in.)
No. 4 transmission hub sleeve clearance 0.15 to 0.41 mm (0.00591 to 0.0161 in.)
Reverse hub shaft snap ring thrust clearance 0.1 mm (0.00394 in.) or less
Reverse hub shaft snap ring thickness A 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
B 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
C 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
D 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
E 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
F 2.50 to 2.55 mm (0.0984 to 0.100 in.)
G 2.55 to 2.60 mm (0.100 to 0.102 in.)
H 2.60 to 2.65 mm (0.102 to 0.104 in.)
No. 3 transmission clutch hub shaft snap ring thrust clearance 0.1 mm (0.00394 in.) or less
No. 3 transmission clutch hub shaft snap ring thickness 1 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
2 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
3 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
4 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
5 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
6 2.50 to 2.55 mm (0.0984 to 0.100 in.)
No. 2 output shaft bearing snap ring thrust clearance 0.1 mm (0.00394 in.) or less
No. 2 output shaft bearing snap ring thickness B 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
C 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
D 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
E 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
Output shaft bearing snap ring thrust clearance 0.1 mm (0.00394 in.) or less
Output shaft bearing snap ring thickness A 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
B 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
C 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
D 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
E 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
F 2.50 to 2.55 mm (0.0984 to 0.100 in.)
G 2.55 to 2.60 mm (0.100 to 0.102 in.)
H 2.60 to 2.65 mm (0.102 to 0.104 in.)
No. 2 transmission clutch hub snap ring thrust clearance 0.1 mm (0.00394 in.) or less
No. 2 transmission clutch hub snap ring thickness 1 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
2 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
3 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
4 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
5 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
6 2.50 to 2.55 mm (0.0984 to 0.100 in.)
Output bearing shaft bearing snap ring thrust clearance 0.1 mm (0.00394 in.) or less
Output bearing shaft snap ring thickness B 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
C 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
D 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
E 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
Shift and Select Lever Shaft
Control shaft cover oil seal standard depth 0 to 0.5 mm (0 to 0.0196 in.)
Inner No. 1 shift lever slotted spring pin standard depth 0.4 to 1.4 mm (0.0158 to 0.0551 in.)