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 |
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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 |
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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 |
Front differential pinion backlash |
Standard Backlash |
0.15 mm (0.00591 in.) or less |
Front No. 1 Differential Side Gear Thrust Washer Thickness 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 Minimum Thickness |
0.54 mm (0.0213 in.) |
Front No. 1 differential pinion shaft |
Minimum Outer Diameter Minimum Outer Diameter |
20.499 mm (0.807 in.) |
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" |