EB61F MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

Manual Transaxle Oil
Capacity Classification
2.4 liters (2.5 US qts, 2.1 Imp.qts) "TOYOTA Genuine Manual Transmission Gear Oil LV" or "API GL-4 and SAE 75W"
Differential Oil Seal (for LH Side)
Transmission case oil seal Depth Standard -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)
Differential Oil Seal (for RH Side)
Front differential case oil seal Depth Standard 21.5 to 22.5 mm (0.847 to 0.885 in.)
Transaxle case oil seal Depth Standard 5.5 to 6.5 mm (0.217 to 0.255 in.)
Back-up Light Switch
Back-up light switch Resistance Pushed Below 1 Ω
Released 10 kΩ or higher
Neutral Position Switch
Neutral position switch assembly Resistance Pushed Below 1 Ω
Released 10 kΩ or higher
Manual Transaxle Unit
Reverse idler gear sub-assembly Inside diameter Standard 20.056 to 20.074 mm (0.7897 to 0.7903 in.)
Maximum 20.074 mm (0.7903 in.)
Outside diameter Standard 19.984 to 20.000 mm (0.7868 to 0.7874 in.)
Maximum 19.984 mm (0.7868 in.)
Straight pin Protrusion height 10.5 to 11.5 mm (0.414 to 0.452 in.)
Differential side bearing Preload New bearing 1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)
Used bearing 0.24 to 0.37 N*m (2.44 to 3.77 kgf*cm, 2.12 to 3.27 in.*lbf)
Differential side shim thickness Thickness A 2.05 mm (0.0807 in.)
B 2.10 mm (0.0827 in.)
C 2.15 mm (0.0846 in.)
D 2.20 mm (0.0866 in.)
E 2.25 mm (0.0886 in.)
F 2.30 mm (0.0906 in.)
G 2.35 mm (0.0925 in.)
H 2.40 mm (0.0945 in.)
J 2.45 mm (0.0965 in.)
K 2.50 mm (0.0984 in.)
L 2.55 mm (0.100 in.)
M 2.60 mm (0.102 in.)
N 2.65 mm (0.104 in.)
P 2.70 mm (0.106 in.)
Q 2.75 mm (0.108 in.)
R 2.80 mm (0.110 in.)
S 2.85 mm (0.112 in.)
T 2.90 mm (0.114 in.)
Output shaft bearing Preload New bearing 3.17 to 6.35 N*m (32 to 65 kgf*cm, 28 to 56 in.*lbf)
Used bearing 2.61 to 5.24 N*m (27 to 53 kgf*cm, 23 to 46 in.*lbf)
Rear output shaft bearing shim Thickness A 1.30 mm (0.0511 in.)
B 1.35 mm (0.0531 in.)
C 1.40 mm (0.0551 in.)
D 1.45 mm (0.0571 in.)
E 1.50 mm (0.0591 in.)
F 1.55 mm (0.0610 in.)
G 1.60 mm (0.0630 in.)
H 1.65 mm (0.0650 in.)
J 1.70 mm (0.0669 in.)
K 1.75 mm (0.0689 in.)
L 1.80 mm (0.0709 in.)
M 1.85 mm (0.0728 in.)
N 1.90 mm (0.0748 in.)
P 1.95 mm (0.0768 in.)
Q 2.00 mm (0.0787 in.)
R 2.05 mm (0.0807 in.)
S 2.10 mm (0.0827 in.)
T 2.15 mm (0.0846 in.)
U 2.20 mm (0.0866 in.)
V 2.25 mm (0.0886 in.)
W 2.30 mm (0.0906 in.)
X 2.35 mm (0.0925 in.)
Y 2.40 mm (0.0945 in.)
Z 2.45 mm (0.0965 in.)
1 2.50 mm (0.0984 in.)
Outer shift lever oil seal Depth Standard 0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Outer No. 1 shift lever Depth Standard -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Front transaxle case oil seal Depth Standard 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
Rear input shaft bearing shim thickness Thickness A 1.15 mm (0.0453 in.)
B 1.20 mm (0.0472 in.)
C 1.25 mm (0.0492 in.)
D 1.30 mm (0.0512 in.)
E 1.35 mm (0.0531 in.)
F 1.40 mm (0.0551 in.)
G 1.45 mm (0.0571 in.)
H 1.50 mm (0.0591 in.)
J 1.55 mm (0.0610 in.)
K 1.60 mm (0.0630 in.)
L 1.65 mm (0.0650 in.)
M 1.70 mm (0.0669 in.)
N 1.75 mm (0.0689 in.)
P 1.80 mm (0.0709 in.)
Outer select lever oil seal Depth Standard 0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Reverse shift fork Driven in depth Standard -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Input Shaft
6th gear Thrust clearance Standard 0.20 to 0.47 mm (0.00788 to 0.01850 in.)
Maximum 0.47 mm (0.01850 in.)
Radial clearance Standard 0.009 to 0.045 mm (0.00036 to 0.00177 in.)
Maximum 0.045 mm (0.00177 in.)
5th gear Thrust clearance Standard 0.20 to 0.47 mm (0.00788 to 0.01850 in.)
Maximum 0.47 mm (0.01850 in.)
Radial clearance Standard 0.009 to 0.045 mm (0.00036 to 0.00177 in.)
Maximum 0.045 mm (0.00177 in.)
4th gear Thrust clearance Standard 0.13 to 0.60 mm (0.00512 to 0.02362 in.)
Maximum 0.60 mm (0.02362 in.)
Radial clearance Standard 0.009 to 0.036 mm (0.00036 to 0.00141 in.)
Maximum 0.036 mm (0.00141 in.)
3rd gear Thrust clearance Standard 0.20 to 0.47 mm (0.00788 to 0.01850 in.)
Maximum 0.47 mm (0.01850 in.)
Radial clearance Standard 0.009 to 0.047 mm (0.00036 to 0.00185 in.)
Maximum 0.047 mm (0.00185 in.)
Input shaft runout Runout Maximum 0.03 mm (0.00118 in.)
Journal diameter Journal A Standard 27.608 to 27.620 mm (1.0870 to 1.0873 in.)
Minimum 27.608 mm (1.0870 in.)
Journal B Standard 41.290 to 41.300 mm (1.6256 to 1.6259 in.)
Minimum 41.290 mm (1.6256 in.)
Journal C Standard 38.280 to 38.300 mm (1.5071 to 1.5078 in.)
Minimum 38.280 mm (1.5071 in.)
Journal D Standard 35.490 to 35.500 mm (1.3973 to 1.3976 in.)
Minimum 35.490 mm (1.3973 in.)
Inner 6th gear bearing race Outer diameter Standard 42.290 to 42.300 mm (1.6650 to 1.6653 in.)
Minimum 42.290 mm (1.6650 in.)
Inside diameter Standard 35.500 to 35.515 mm (1.3977 to 1.3982 in.)
Minimum 35.515 mm (1.3982 in.)
Inner 5th gear bearing race Outer diameter Standard 45.290 to 45.300 mm (1.7831 to 1.7834 in.)
Minimum 45.290 mm (1.7831 in.)
Inside diameter Standard 38.300 to 38.315 mm (1.5079 to 1.5084 in.)
Minimum 38.315 mm (1.5084 in.)
6th gear Inside diameter Standard 47.309 to 47.325 mm (1.8626 to 1.8631 in.)
Maximum 47.325 mm (1.8631 in.)
5th gear Inside diameter Standard 50.309 to 50.325 mm (1.9807 to 1.9812 in.)
Maximum 50.325 mm (1.9812 in.)
4th gear Inside diameter Standard 47.301 to 47.317 mm (1.8623 to 1.8628 in.)
Maximum 47.317 mm (1.8628 in.)
3rd gear Inside diameter Standard 47.309 to 47.325 mm (1.8626 to 1.8631 in.)
Maximum 47.325 mm (1.8631 in.)
No. 5 synchronizer ring Clearance Standard 0.88 to 1.52 mm (0.0347 to 0.0598 in.)
Minimum 0.88 mm (0.0347 in.)
No. 4 synchronizer ring Clearance Standard 0.88 to 1.72 mm (0.0347 to 0.0677 in.)
Minimum 0.88 mm (0.0347 in.)
No. 3 synchronizer ring Clearance Standard 0.78 to 1.62 mm (0.0308 to 0.0637 in.)
Minimum 0.78 mm (0.0308 in.)
No. 2 transmission hub sleeve Clearance (A - B) Standard 0.1 to 0.5 mm (0.00394 to 0.01968 in.)
No. 3 transmission hub sleeve Clearance (A - B) Standard 0.1 to 0.5 mm (0.00394 to 0.01968 in.)
No. 2 clutch hub setting shaft snap ring Clearance Standard 0.1 mm (0.00394 in.) or less
Thickness 0 2.30 mm (0.0905 in.)
1 2.36 mm (0.0929 in.)
2 2.42 mm (0.0952 in.)
3 2.48 mm (0.0976 in.)
4 2.54 mm (0.0999 in.)
5 2.60 mm (0.1023 in.)
Rear input shaft bearing shaft snap ring Clearance Standard 0.1 mm (0.00394 in.) or less
Thickness 0 1.90 mm (0.0748 in.)
1 1.96 mm (0.0771 in.)
2 2.02 mm (0.0795 in.)
3 2.08 mm (0.0818 in.)
4 2.14 mm (0.0842 in.)
5 2.20 mm (0.0866 in.)
6 2.26 mm (0.0889 in.)
7 2.32 mm (0.0913 in.)
8 2.38 mm (0.0937 in.)
9 2.44 mm (0.0960 in.)
A 2.50 mm (0.0984 in.)
Output Shaft
1st gear Thrust clearance Standard 0.23 to 0.37 mm (0.00906 to 0.01456 in.)
Maximum 0.37 mm (0.01456 in.)
Radial clearance Standard 0.009 to 0.047 mm (0.00036 to 0.00185 in.)
Maximum 0.047 mm (0.00185 in.)
2nd gear Thrust clearance Standard 0.16 to 0.33 mm (0.00630 to 0.01299 in.)
Maximum 0.33 mm (0.01299 in.)
Radial clearance Standard 0.009 to 0.047 mm (0.000336 to 0.00185 in.)
Maximum 0.047 mm (0.00185 in.)
Output shaft Runout Maximum 0.03 mm (0.00118 in.)
Output shaft journal diameter Journal A Standard 28.010 to 28.023 mm (1.1028 to 1.1032 in.)
Minimum 28.010 mm (1.1028 in.)
Journal B Standard 42.180 to 42.200 mm (1.6607 to 1.6614 in.)
Minimum 42.180 mm (1.6607 in.)
Journal C Standard 36.010 to 36.026 mm (1.4178 to 1.4183 in.)
Minimum 36.010 mm (1.4178 in.)
1st gear Inside diameter Standard 57.909 to 57.925 mm (2.2799 to 2.2805 in.)
Maximum 57.925 mm (2.2805 in.)
2nd gear Inside diameter Standard 57.909 to 57.925 mm (2.2799 to 2.2805 in.)
Maximum 57.925 mm (2.2805 in.)
1st gear bush Outer diameter Standard 51.890 to 51.900 mm (2.0430 to 2.0433 in.)
Minimum 51.890 mm (2.0430 in.)
Inside diameter Standard 42.200 to 42.215 mm (1.6615 to 1.6620 in.)
Maximum 42.215 mm (1.6620 in.)
Inner 2nd gear bearing race Outer diameter Standard 51.890 to 51.900 mm (2.0430 to 2.0433 in.)
Minimum 51.890 mm (2.0430 in.)
Inside diameter Standard 42.200 to 42.215 mm (1.6615 to 1.6620 in.)
Maximum 42.215 mm (1.6620 in.)
No. 1 synchronizer ring set Clearance 1st gear side Standard 0.88 to 1.72 mm (0.0347 to 0.0677 in.)
Minimum 0.88 mm (0.0347 in.)
2nd gear side Standard 0.88 to 1.72 mm (0.0347 to 0.0677 in.)
Minimum 0.88 mm (0.0347 in.)
Reverse gear Clearance (A - B) Standard 0.1 to 0.5 mm (0.00394 to 0.01968 in.)
Shift and Select Lever Shaft
Release head Depth Standard -0.2 to 0.8 mm (-0.00787 to 0.0315 in.)
Front inner shift lever Depth Standard -0.2 to 0.8 mm (-0.00787 to 0.0315 in.)
Inner No. 2 shift lever Depth Standard 0 to 0.6 mm (0 to 0.0236 in.)
Differential Case
Front differential side gear Thrust amount Standard 0.08 mm (0.00314 in.) or less
Front differential pinion backlash Backlash Standard 0.20 mm (0.00787 in.) or less
Front No. 1 differential side gear thrust washer Thickness 1 1.00 mm (0.0394 in.)
2 1.10 mm (0.0433 in.)
3 1.20 mm (0.0472 in.)
4 1.30 mm (0.0512 in.)
Front differential pinion thrust washer Thickness Minimum 0.9 mm (0.0354 in.)
Front No. 1 differential pinion shaft Outer diameter Minimum 17.975 mm (0.708 in.)