EA66 MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

Manual transaxle assembly unit
Reverse idler gear thrust clearance Standard 0.40 to 1.05 mm (0.0157 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 0.00189 in.)
Maximum 0.048 mm (0.00189 in.)
Transmission case oil seal depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Transaxle case oil seal depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Shift fork shaft bearing depth 0 to 0.5 mm (0.000 to 0.0197 in.)
Transaxle case oil seal depth 4.4 to 5.0 mm (0.173 to 0.197 in.)
Shift and select lever shaft needle roller bearing depth 177.8 to 178.7 mm (7.00 to 7.04 in.)
Shift fork shaft bearing depth (Clearance A) 168.2 to 169.3 mm (6.62 to 6.67 in.)
Shift fork shaft bearing depth (Clearance B) 162.2 to 163.3 mm (6.39 to 6.43 in.)
Front differential case rear shim thickness 0 1.99 to 2.01 (0.0783 to 0.0791 in.)
1 2.04 to 2.06 (0.0803 to 0.0811 in.)
2 2.09 to 2.11 (0.0823 to 0.0831 in.)
3 2.14 to 2.16 (0.0843 to 0.0850 in.)
4 2.19 to 2.21 (0.0862 to 0.0870 in.)
5 2.24 to 2.26 (0.0882 to 0.0890 in.)
6 2.29 to 2.31 (0.0902 to 0.0909 in.)
7 2.34 to 2.36 (0.0921 to 0.0929 in.)
8 2.39 to 2.41 (0.0941 to 0.0949 in.)
9 2.44 to 2.46 (0.0961 to 0.0969 in.)
A 2.49 to 2.51 (0.0980 to 0.0988 in.)
B 2.54 to 2.56 (0.1000 to 0.1008 in.)
C 2.59 to 2.61 (0.1020 to 0.1028 in.)
D 2.64 to 2.66 (0.1039 to 0.1047 in.)
E 2.69 to 2.71 (0.1059 to 0.1067 in.)
F 2.74 to 2.76 (0.1079 to 0.1087 in.)
G 2.79 to 2.81 (0.1098 to 0.1106 in.)
H 2.84 to 2.86 (0.1118 to 0.1126 in.)
No. 2 output shaft rear bearing shim thickness A 1.79 to 1.81 (0.0705 to 0.0713 in.)
B 1.84 to 1.86 (0.0724 to 0.0732 in.)
C 1.89 to 1.91 (0.0744 to 0.0752 in.)
D 1.94 to 1.96 (0.0764 to 0.0772 in.)
E 1.99 to 2.01 (0.0783 to 0.0791 in.)
F 2.04 to 2.06 (0.0803 to 0.0811 in.)
G 2.09 to 2.11 (0.0823 to 0.0831 in.)
H 2.14 to 2.16 (0.0843 to 0.0850 in.)
J 2.19 to 2.21 (0.0862 to 0.0870 in.)
K 2.24 to 2.26 (0.0882 to 0.0890 in.)
L 2.29 to 2.31 (0.0902 to 0.0909 in.)
M 2.34 to 2.36 (0.0921 to 0.0929 in.)
N 2.39 to 2.41 (0.0941 to 0.0949 in.)
P 2.44 to 2.46 (0.0961 to 0.0969 in.)
Q 2.49 to 2.51 (0.0980 to 0.0988 in.)
R 2.54 to 2.56 (0.1000 to 0.1008 in.)
S 2.59 to 2.61 (0.1020 to 0.1028 in.)
T 2.64 to 2.66 (0.1039 to 0.1047 in.)
No. 5 gear shift fork shaft slotted spring pin depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
3rd and 4th shift fork shaft slotted spring pin depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Differential side bearing preload New bearing preload 1.00 to 2.49 N*m (10 to 25 kgf*cm, 9 to 22 in.*lbf)
No. 2 output shaft rear bearing preload New bearing preload 3.66 to 5.18 N*m (37 to 53 kgf*cm, 32 to 46 in.*lbf)
Input shaft assembly
Input shaft runout Maximum 0.03 mm (0.00118 in.)
Input shaft outer diameter Measured Part A 30.008 to 30.020 (1.1814 to 1.1819)
Measured Part B 32.002 to 32.018 (1.2599 to 1.2605)
Input shaft rear bearing shaft snap ring A 1.80 to 1.85 (0.0709 to 0.0728 in.)
B 1.85 to 1.90 (0.0728 to 0.0748 in.)
C 1.90 to 1.95 (0.0748 to 0.0768 in.)
D 1.95 to 2.00 (0.0768 to 0.0787 in.)
E 2.00 to 2.05 (0.0787 to 0.0807 in.)
0 2.05 to 2.10 (0.0807 to 0.0827 in.)
1 2.10 to 2.15 (0.0827 to 0.0846 in.)
2 2.15 to 2.20 (0.0846 to 0.0866 in.)
3 2.20 to 2.25 (0.0866 to 0.0886 in.)
4 2.25 to 2.30 (0.0886 to 0.0906 in.)
5 2.30 to 2.35 (0.0906 to 0.0925 in.)
6 2.35 to 2.40 (0.0925 to 0.0945 in.)
F 2.40 to 2.45 (0.0945 to 0.0965 in.)
G 2.45 to 2.50 (0.0965 to 0.0984 in.)
H 2.50 to 2.55 (0.0984 to 0.1004 in.)
No. 1 output shaft assembly
No. 1 output shaft runout Maximum 0.03 mm (0.00118 in.)
No. 1 output shaft outer diameter Measured part A 32.002 to 32.018 (1.2599 to 1.2605 in.)
Measured part B 35.984 to 36.000 (1.4167 to 1.4173 in.)
Measured part C 41.984 to 42.000 (1.6529 to 1.6535 in.)
Measured part D 41.989 to 42.000 (1.6531 to 1.6535 in.)
Measured part E 46.984 to 47.000 (1.8498 to 1.8504 in.)
Measured part F 36.002 to 36.018 (1.4174 to 1.4180 in.)
1st driven gear thrust clearance Standard clearance 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum clearance 0.35 mm (0.0138 in.)
2nd driven gear thrust clearance Standard clearance 0.11 to 0.46 mm (0.00433 to 0.0181 in.)
Maximum clearance 0.46 mm (0.0181 in.)
3rd driven gear thrust clearance Standard clearance 0.11 to 0.54 mm (0.00433 to 0.0213 in.)
Maximum clearance 0.54 mm (0.0213 in.)
4th driven gear thrust clearance Standard clearance 0.10 to 0.65 mm (0.00394 to 0.0256 in.)
Maximum clearance 0.65 mm (0.0256 in.)
1st driven gear radial clearance Standard clearance 0.015 to 0.068 mm (0.000591 to 0.00268 in.)
Maximum clearance 0.068 mm (0.00268 in.)
2nd driven gear radial clearance Standard clearance 0.015 to 0.048 mm (0.000591 to 0.00189 in.)
Maximum clearance 0.048 mm (0.00189 in.)
3rd driven gear radial clearance Standard clearance 0.015 to 0.066 mm (0.000591 to 0.0026 in.)
Maximum clearance 0.066 mm (0.0026 in.)
4th driven gear radial clearance Standard clearance 0.015 to 0.066 mm (0.000591 to 0.0026 in.)
Maximum clearance 0.066 mm (0.0026 in.)
1st and 2nd shift fork shaft outer diameter Standard outer diameter 13.982 to 14.00 mm (0.5505 to 0.5512 in.)
Minimum outer diameter 13.982 mm (0.5505 in.)
3rd and 4th shift fork shaft outer diameter Standard outer diameter 13.982 to 14.00 mm (0.5505 to 0.5512 in.)
Minimum outer diameter 13.982 mm (0.5505 in.)
5th and 6th shift fork shaft outer diameter Standard outer diameter 13.982 to 14.00 mm (0.5505 to 0.5512 in.)
Minimum outer diameter 13.982 mm (0.5505 in.)
Reverse shift fork shaft outer diameter Standard outer diameter 13.982 to 14.00 mm (0.5505 to 0.5512 in.)
Minimum outer diameter 13.982 mm (0.5505 in.)
No. 5 gear shift fork shaft outer diameter Standard outer diameter 15.966 to 15.984 mm (0.6286 to 0.6293 in.)
Minimum outer diameter 15.966 mm (0.6286 in.)
No. 1 gear shift fork inside diameter and thickness Thickness 9.50 to 9.80 mm (0.374 to 0.386 in.)
Inside diameter 14.010 to 14.043 mm (0.552 to 0.553 in.)
No. 2 gear shift fork inside diameter and thickness Thickness 9.50 to 9.80 mm (0.374 to 0.386 in.)
Inside diameter 14.010 to 14.043 mm (0.552 to 0.553 in.)
Inside diameter 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 (0.374 to 0.386 in.)
Inside diameter 14.010 to 14.043 mm (0.552 to 0.553 in.)
Reverse shaft fork inside diameter and thickness Thickness 4.40 to 4.56 mm (0.173 to 0.178 in.)
Inside diameter 14.010 to 14.043 mm (0.552 to 0.553 in.)
Inside diameter 14.7 to 15.3 mm (0.579 to 0.602 in.)
No. 2 gear shift head inside diameter Standard inside diameter 13.994 to 14.054 mm (0.551 to 0.553 in.)
Maximum inside diameter 14.054 mm (0.553 in.)
No. 3 gear shift head inside diameter Standard inside diameter A 15.994 to 16.054 mm (0.630 to 0.632 in.)
Standard inside diameter B 14.20 to 14.25 mm (0.559 to 0.561 in.)
Maximum inside diameter A 16.054 mm (0.632 in.)
Maximum inside diameter B 14.25 mm (0.561 in.)
1st driven gear inside diameter Standard inside diameter 53.015 to 53.040 mm (2.0872 to 2.0882 in.)
Maximum inside diameter 53.040 mm (2.0882 in.)
2nd driven gear inside diameter Standard inside diameter 56.015 to 56.030 mm (2.2053 to 2.2059 in.)
Maximum inside diameter 56.030 mm (2.2059 in.)
3rd driven gear inside diameter Standard inside diameter 42.015 to 42.040 mm (1.6541 to 1.6551 in.)
Maximum inside diameter 42.040 mm (1.6551 in.)
4th driven gear inside diameter Standard inside diameter 48.015 to 48.040 mm (1.8904 to 1.8913 in.)
Maximum inside diameter 48.040 mm (1.8913 in.)
1st driven gear synchronizer ring clearance Standard clearance 0.98 to 1.82 mm (0.0386 to 0.0717 in.)
Minimum clearance 0.98 mm (0.0386 in.)
2nd driven gear synchronizer ring clearance Standard clearance 1.08 to 1.92 mm (0.0425 to 0.0756 in.)
Minimum clearance 1.08 mm (0.0425 in.)
3rd driven gear synchronizer ring clearance Standard clearance 1.00 to 2.00 mm (0.0394 to 0.0787 in.)
Minimum clearance 1.00 mm (0.0394 in.)
4th driven gear synchronizer ring clearance Standard clearance 0.92 to 1.88 mm (0.0362 to 0.074 in.)
Minimum clearance 0.92 mm (0.0362 in.)
No. 1 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0197 in.)
No. 2 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0197 in.)
No. 2 output shaft assembly
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 (1.2599 to 1.2605)
Measured Part B 35.984 to 36.000 (1.4167 to 1.4173)
Measured Part C 41.984 to 42.000 (1.6529 to 1.6535)
Measured Part D 46.984 to 47.000 (1.8498 to 1.8504)
Measured Part E 35.002 to 35.018 (1.3780 to 1.3787)
5th driven gear thrust clearance Standard clearance 0.10 to 0.55 mm (0.00394 to 0.0217 in.)
Maximum clearance 0.55 mm (0.0217 in.)
6th driven gear thrust clearance Standard clearance 0.10 to 0.55 mm (0.00394 to 0.0217 in.)
Maximum clearance 0.55 mm (0.0217 in.)
Reverse driven gear thrust clearance Standard clearance 0.11 to 0.34 mm (0.00433 to 0.0134 in.)
Maximum clearance 0.34 mm (0.0134 in.)
5th driven gear radial clearance Standard clearance 0.015 to 0.066 mm (0.000591 to 0.0026 in.)
Maximum clearance 0.066 mm (0.0026 in.)
6th driven gear radial clearance Standard clearance 0.015 to 0.066 mm (0.000591 to 0.0026 in.)
Maximum clearance 0.066 mm (0.0026 in.)
Reverse driven gear radial clearance Standard clearance 0.015 to 0.068 mm (0.000591 to 0.00268 in.)
Maximum clearance 0.068 mm (0.00268 in.)
5th driven gear inside diameter Standard clearance 48.015 to 48.040 mm (1.8904 to 1.8913 in.)
Maximum clearance 48.040 mm (1.8913 in.)
6th driven gear inside diameter Standard clearance 42.015 to 42.040 mm (1.6541 to 1.6551in.)
Maximum clearance 42.040 mm (1.6551 in.)
Reverse driven gear inside diameter Standard clearance 53.015 to 53.040 mm (2.0872 to 2.0882 in.)
Maximum clearance 53.040 mm (2.0882 in.)
5th driven gear synchronizer ring clearance Standard clearance 0.80 to 1.60 mm (0.0315 to 0.063 in.)
Minimum clearance 0.80 mm (0.0315 in.)
6th driven gear synchronizer ring clearance Standard clearance 0.80 to 1.60 mm (0.0315 to 0.063 in.)
Minimum clearance 0.80 mm (0.0315 in.)
Reverse driven gear synchronizer ring clearance Standard clearance 0.68 to 1.32 mm (0.0268 to 0.052 in.)
Minimum clearance 0.68 mm (0.0268 in.)
No. 3 transmission hub sleeve clearance 0.10 to 0.50 mm (0.00394 to 0.0197 in.)
No. 4 transmission hub sleeve clearance 0.15 to 0.41 mm (0.00591 to 0.0161 in.)
No. 4 transmission clutch hub shaft snap ring A 2.25 to 2.30 (0.0886 to 0.0906 in.)
B 2.30 to 2.35 (0.0906 to 0.0925 in.)
C 2.35 to 2.40 (0.0925 to 0.0945 in.)
D 2.40 to 2.45 (0.0945 to 0.0965 in.)
E 2.45 to 2.50 (0.0965 to 0.0984 in.)
F 2.50 to 2.55 (0.0984 to 0.1004in.)
G 2.55 to 2.60 (0.1004 to 0.1024 in.)
H 2.60 to 2.65 (0.1024 to 0.1043 in.)
No. 3 transmission clutch hub shaft snap ring 1 2.25 to 2.30 (0.0886 to 0.0906 in.)
2 2.30 to 2.35 (0.0906 to 0.0925 in.)
3 2.35 to 2.40 (0.0925 to 0.0945 in.)
4 2.40 to 2.45 (0.0945 to 0.0965 in.)
5 2.45 to 2.50 (0.0965 to 0.0984 in.)
6 2.50 to 2.55 (0.0984 to 0.1004 in.)
No. 2 output shaft bearing snap ring B 1.85 to 1.90 (0.0728 to 0.0748 in.)
C 1.90 to 1.95 (0.0748 to 0.0768 in.)
D 1.95 to 2.00 (0.0768 to 0.0787 in.)
E 2.00 to 2.05 (0.0787 to 0.0807 in.)
0 2.05 to 2.10 (0.0807 to 0.0827 in.)
1 2.10 to 2.15 (0.0827 to 0.0846 in.)
2 2.15 to 2.20 (0.0846 to 0.0866 in.)
Output shaft bearing snap ring A 2.25 to 2.30 (0.0886 to 0.0906 in.)
B 2.30 to 2.35 (0.0906 to 0.0925 in.)
C 2.35 to 2.40 (0.0925 to 0.0945 in.)
D 2.40 to 2.45 (0.0945 to 0.0965 in.)
E 2.45 to 2.50 (0.0965 to 0.0984 in.)
F 2.50 to 2.55 (0.0984 to 0.1004 in.)
G 2.55 to 2.60 (0.1004 to 0.1024 in.)
H 2.60 to 2.65 (0.1024 to 0.1043 in.)
No. 2 transmission clutch hub shaft snap ring 1 2.25 to 2.30 (0.0886 to 0.0906 in.)
2 2.30 to 2.35 (0.0906 to 0.0925 in.)
3 2.35 to 2.40 (0.0925 to 0.0945 in.)
4 2.40 to 2.45 (0.0945 to 0.0965 in.)
5 2.45 to 2.50 (0.0965 to 0.0984 in.)
6 2.50 to 2.55 (0.0984 to 0.1004 in.)
Output shaft bearing shaft snap ring B 1.85 to 1.90 (0.0728 to 0.0748 in.)
C 1.90 to 1.95 (0.0748 to 0.0768 in.)
D 1.95 to 2.00 (0.0768 to 0.0787 in.)
E 2.00 to 2.05 (0.0787 to 0.0807 in.)
0 2.05 to 2.10 (0.0807 to 0.0827 in.)
1 2.10 to 2.15 (0.0827 to 0.0846 in.)
2 2.15 to 2.20 (0.0846 to 0.0866 in.)
shift and select lever shaft
Control shaft cover oil seal depth 0 to 0.5 mm (0 to 0.0197 in.)
No. 1 shift lever inner pin depth 3.5 to 4.5 mm (0.138 to 0.177 in.)
No. 1 shift lever inner slotted spring pin depth 0.4 to 1.4 mm (0.0157 to 0.0551 in.)
Differential case
Back-up light switch

Push

Release

Below 1 Ω

10 kΩ or higher
Differential Case
Front differential pinion backlash Standard Backlash 0.15 mm (0.00591 in.) or less
Front No. 1 Differential Side Gear Thrust Washer Thickness 1.25 mm (0.0492 in.)
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.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
Front differential pinion thrust washer Minimum Thickness 0.54 mm (0.0213 in.)
Front No. 1 differential pinion shaft Minimum Outer Diameter 20.499 mm (0.807 in.)
Manual Transaxle Oil
Capacity Classification
2.1 liters (2.2 US qts, 1.8 Imp. qts) "Toyota Genuine Manual Transmission Gear Oil LV GL-4 and SAE 75W" or "API GL-4 and SAE 75W"