EC60 MANUAL TRANSMISSION / TRANSAXLE SERVICE DATA

Differential Oil Seal
Transmission case oil seal
Installation depth Standard 10.6 to 11.6 mm (0.417 to 0.457 in.)
Front transaxle case oil seal
Installation depth Standard 1.4 to 2.4 mm (0.0551 to 0.0945 in.)
Back-up Light Switch

Resistance

1 - 2

Standard

Pushed

Released

Below 1 Ω

10 kΩ or higher
Neutral Position Switch

Resistance

1 - 2

Standard

Pushed

Released

Below 1 Ω

10 kΩ or higher
Manual Transaxle Unit
Reverse idler gear
Inside diameter

Standard

Maximum

25.056 to 25.074 mm (0.9864 to 0.9871 in.)

25.074 mm (0.9871 in.)
Reverse idler gear shaft
Outside diameter

Standard

Maximum

24.984 to 25.000 mm (0.9836 to 0.9842 in.)

24.984 mm (0.9836 in.)
Differential side bearing preload

New bearing

Used bearing

1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)

0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)
Differential side shim 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 (0.100 in.)

2.575 mm (0.101 in.)

2.600 mm (0.102 in.)

2.625 mm (0.103 in.)

2.650 mm (0.104 in.)

2.675 mm (0.105 in.)

2.700 mm (0.106 in.)

2.725 mm (0.107 in.)

2.750 mm (0.108 in.)

2.775 mm (0.109 in.)

2.800 mm (0.110 in.)

2.825 mm (0.111 in.)

2.850 mm (0.112 in.)
Output shaft bearing preload
New bearing

1ZR-FAE

2ZR-FAE

4.6 to 8.0 N*m (47 to 81 kgf*cm, 41 to 70 in.*lbf)

4.3 to 7.6 N*m (44 to 78 kgf*cm, 38 to 67 in.*lbf)
Used bearing

1ZR-FAE

2ZR-FAE

3.0 to 5.2 N*m (31 to 53 kgf*cm, 27 to 46 in.*lbf)

2.8 to 4.9 N*m (29 to 50 kgf*cm, 25 to 43 in.*lbf)
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 (0.100 in.)

2.575 mm (0.101 in.)

2.600 mm (0.102 in.)

2.625 mm (0.103 in.)

2.650 mm (0.104 in.)

2.675 mm (0.105 in.)

2.700 mm (0.106 in.)

2.725 mm (0.107 in.)

2.750 mm (0.108 in.)

2.775 mm (0.109 in.)

2.800 mm (0.110 in.)
Outer shift lever oil seal Standard depth 0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Outer No. 1 shift lever Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Front transaxle case oil seal Standard depth 0.9 to 1.9 mm (0.0354 to 0.0748 in.)
Rear input shaft bearing shim thickness

10

11

12

13

14

15

16

17

18

19

20

21

22

23

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.)

2.00 mm (0.0787 in.)

2.05 mm (0.0807 in.)
Outer select lever oil seal Standard depth 0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Input Shaft
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 0.075 mm (0.000354 to 0.00295 in.)

0.009 to 0.075 mm (0.000354 to 0.00295 in.)
Maximum

3rd

4th

5th

6th

0.050 mm (0.0197 in.)

0.050 mm (0.0197 in.)

0.075 mm (0.00295 in.)

0.075 mm (0.00295 in.)
Input shaft
Runout Maximum 0.015 mm (0.000590 in.)
Outer diameter
Standard

Part A

Part B

Part C

Part D

25.002 to 25.017 mm (0.9844 to 0.9849 in.)

37.485 to 37.500 mm (1.4758 to 1.4763 in.)

31.690 to 31.700 mm (1.2477 to 1.2480 in.)

27.990 to 28.000 mm (1.1020 to 1.1023 in.)
Minimum

Part A

Part B

Part C

Part D

25.002 mm (0.9844 in.)

37.485 mm (1.4758 in.)

31.690 mm (1.2477 in.)

27.990 mm (1.1020 in.)
Gear bearing race outer diameter
Standard

5th

6th

37.49 to 37.50 mm (1.4760 to 1.4763 in.)

35.09 to 35.10 mm (1.3815 to 1.3818 in.)
Maximum

5th

6th

37.49 mm (1.4760in.)

35.09 mm (1.3815 in.)
Gear bearing race inside diameter
Standard

5th

6th

31.705 to 31.720 mm (1.2483 to 1.2488 in.)

28.005 to 28.020 mm (1.1026 to 1.1031 in.)
Minimum

5th

6th

31.720 mm (1.2488 in.)

28.020 mm (1.1031 in.)
Gear inside diameter
Standard

3rd

4th

5th

6th

42.509 to 42.525 mm (1.6736 to 1.6742 in.)

42.509 to 42.525 mm (1.6736 to 1.6742 in.)

42.509 to 42.525 mm (1.6736 to 1.6742 in.)

40.109 to 40.125 mm (1.5791 to 1.5797 in.)
Maximum

3rd

4th

5th

6th

42.525 mm (1.6742 in.)

42.525 mm (1.6742 in.)

42.525 mm (1.6742 in.)

40.125 mm (1.5797 in.)
Synchronizer ring clearance
Standard

No. 3

No. 5

0.78 to 1.58 mm (0.0308 to 0.0622 in.)

0.73 to 1.53 mm (0.0288 to 0.0602 in.)
Minimum

No. 3

No. 5

0.78 mm (0.0308 in.)

0.73 mm (0.0288 in.)
Outer 2nd synchronizer ring
Clearance

Standard

Minimum

0.78 to 1.58 mm (0.0308 to 0.0622 in.)

0.78 mm (0.0308 in.)
Transmission hub sleeve
Standard clearance

No. 2

No. 3

0.1 to 0.5 mm (0.00394 to 0.0196 in.)

0.1 to 0.5 mm (0.00394 to 0.0196 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 (0.101 in.)

2.62 mm (0.103 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 (0.0649 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.)
Output Shaft
Thrust clearance
Standard

1st

2nd

0.20 to 0.38 mm (0.00788 to 0.0149 in.)

0.15 to 0.33 mm (0.00591 to 0.0129 in.)
Maximum

1st

2nd

0.38 mm (0.0149 in.)

0.33 mm (0.0129 in.)

Radial clearance

for TMC Made
Standard

1st

2nd

0.009 to 0.077 mm (0.000355 to 0.00303 in.)

0.009 to 0.077 mm (0.000355 to 0.00303 in.)
Maximum

1st

2nd

0.077 mm (0.00303 in.)

0.077 mm (0.00303 in.)

Radial clearance

for except TMC Made
Standard

1st

2nd

0.009 to 0.075 mm (0.000355 to 0.00295 in.)

0.009 to 0.075 mm (0.000355 to 0.00295 in.)
Maximum

1st

2nd

0.075 mm (0.00295 in.)

0.075 mm (0.00295 in.)
Output shaft runout Maximum 0.015 mm (0.000590 in.)
Output shaft outer diameter
Standard

A

B

C

D

30.002 to 30.017 mm (1.1812 to 1.1817 in.)

37.990 to 38.000 mm (1.4957 to 1.4960 in.)

40.790 to 40.800 mm (1.6060 to 1.6062 in.)

28.002 to 28.017 mm (1.1025 to 1.1030 in.)
Minimum

A

B

C

D

30.002 mm (1.1812 in.)

37.990 mm (1.4957 in.)

40.790 mm (1.6060 in.)

28.002 mm (1.1025 in.)
Gear inside diameter
Standard

1st

2nd

52.909 to 52.925 mm (2.0831 to 2.0836 in.)

52.909 to 52.925 mm (2.0831 to 2.0836 in.)
Maximum

1st

2nd

52.925 mm (2.0836 in.)

52.925 mm (2.0836 in.)
1st gear bush
Outer diameter

Standard

Minimum

47.89 to 47.90 mm (1.8855 to 1.8858 in.)

47.89 mm (1.8855 in.)
Inside diameter

Standard

Maximum

40.805 to 40.820 mm (1.6065 to 1.6070 in.)

40.820 mm (1.6070 in.)
Inner 2nd gear bearing race
Outer diameter

Standard

Minimum

47.89 to 47.90 mm (1.8855 to 1.8858 in.)

47.89 mm (1.88558 in.)
Inside diameter

Standard

Maximum

38.005 to 38.020 mm (1.4963 to 1.4968 in.)

38.020 mm (1.4968 in.)
No. 1 synchronizer ring set clearance
Standard

1st gear side

2nd gear side

0.915 to 1.855 mm (0.0361 to 0.0730 in.)

0.92 to 1.86 mm (0.0363 to 0.0732 in.)
Minimum

1st gear side

2nd gear side

0.915 mm (0.0361 in.)

0.92 mm (0.0363 in.)
Reverse gear clearance Standard 0.1 to 0.5 mm (0.00394 to 0.0196 in.)
Shift and Select Lever Shaft
Select stopper block Standard depth -0.2 to 0.8 mm (-0.00787 to 0.0314 in.)
Release head straight pin Standard depth -0.2 to 0.8 mm (-0.00787 to 0.0314 in.)
No. 2 shift lever Standard depth 0 to 0.6 mm (0 to 0.0236 in.)
Differential Case
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 mm (0.0374 in.)

1.00 mm (0.0394 in.)

1.05 mm (0.0413 in.)

1.10 mm (0.0433 in.)

1.15 mm (0.0452 in.)

1.20 mm (0.0472 in.)
Front differential pinion thrust washer
Thickness

Standard

Minimum

0.92 to 1.08 mm (0.0363 to 0.0425 in.)

0.92 mm (0.0363 in.)
Front No. 1 differential pinion shaft
Outer diameter

Standard

Minimum

16.982 to 17.000 mm (0.6686 to 0.6692 in.)

16.982 mm (0.6686 in.)
Manual Transmission Oil
Capacity Oil Classification
2.4 liters (2.5 US qts, 2.1 Imp. qts) API GL-4 and SAE 75W