EA64F Manual Transmission Specifications Toyota RAV4

Notes:

Below are the standard technical parameters of the parts and mechanisms of the EA64F mechanical transmission for comparison with the results obtained during the diagnosis and elimination of the identified malfunction.

Mechanical transmission assembly.

1) Radial clearance of reverse idler gear - 0.40-1.05 mm (0.0016-0.0413 in.) nominal; maximum 1.05 mm (0.0413 in.).

2) Axial clearance of reverse idler gear - nominal value 0.015-0.048 mm (0.0006-0.0019 in.); maximum 0.048 mm (0.0019 in.).

3) The installation depth of the front transmission case cover oil seal is -0.5 to 0.5 mm (-0.0197 to 0.0197 in.).

4) The installation depth of the shift bar bearing is 0-0.5 mm (0-0.0197 in.).

5) The installation depth of the transmission case oil seal is 4.4-5.0 mm (0.1732-0.1969 in.).

6) The installation depth of the gear lever shaft needle roller bearing is 177.8 to 178.7 mm (7.0000 to 7.0354 inches).

7) The installation depth of the shift bar bearing (A) is 168.2 to 169.3 mm (6.6220 to 6.6653 inches).

8) Thickness of front differential housing rear shim - 0: 1.99-2.01 mm (0.0783-0.0791 in.); 1: 2.04 - 2.06 mm (0.0803 - 0.0811 inches); 2: 2.09–2.11 mm (0.0823–0.0831 in); 3: 2.14-2.16 mm (0.0843-0.0850 in); 4: 2.19–2.21 mm (0.0862–0.0870 in); 5: 2.24–2.26 mm (0.0882–0.0890 in); 6: 2.29–2.31 mm (0.0902–0.0909 in); 7: 2.34–2.36 mm (0.0921–0.0929 in); 8: 2.39–2.41 mm (0.0941–0.0949 in); 9: 2.44–2.46 mm (0.0961–0.0969 in); A: 2.49–2.51 mm (0.0981–0.0988 in); H: 2.54 - 2.56 mm (0.1000 - 0.1008 in); C: 2.59–2.61 mm (0.1020–0.1028 in); D: 2.64 - 2.66 mm (0.1039 - 0.1047 in); E: 2.69–2.71 mm (0.1059–0.1067 in); F: 2.74 - 2.76 mm (0.1079 - 0.1087 in); G: 2.79 - 2.81 mm (0.1098 - 0.1106 inches); H: 2.84–2.86 mm (0.1118–0.1126 in.).

9) #2 output shaft rear bearing washer thickness - A: 1.79-1.81 mm (0.0705-0.0713 in.); H: 1.84 - 1.86 mm (0.0724 - 0.0732 in); C: 1.89–1.91 mm (0.0744–0.0752 in); D: 1.94 - 1.96 mm (0.0764 - 0.0772 in); E: 1.99–2.01 mm (0.0783–0.0791 in); F: 2.04 - 2.06 mm (0.0803 - 0.0811 in); G: 2.09 - 2.11 mm (0.0823 - 0.0831 in); H: 2.14–2.16 mm (0.0843–0.0850 in); J: 2.19 - 2.21 mm (0.0862 - 0.0870 in); K: 2.24–2.26 mm (0.0882–0.0890 in); L: 2.29 - 2.31 mm (0.0902 - 0.0909 in); M: 2.34-2.36 mm (0.0921-0.0929 in); N: 2.39-2.41 mm (0.0941-0.0949 in); P: 2.44–2.46 mm (0.0961–0.0969 in); Q: 2.49 - 2.51 mm (0.0980 - 0.0988 in); R: 2.54-2.56 mm (0.1000-0.1008 in); S: 2.59 - 2.61 mm (0.1020 - 0.1028 in); T: 2.64–2.66 mm (0.1039–0.1047 in.).

10) The installation depth of the #5 shift bar pin is -0.5 to 0.5 mm (-0.0197 to 0.0197 in.).

11) The installation depth of the #3 and #4 shift bar pin is -0.5 to 0.5 mm (-0.0197 to 0.0197 inches).

12) Differential side bearing preload (for new bearing) - 1.00 - 2.49 N m (10.2 - 25.4 kgf cm, 8.85 - 22.04 lbf in).

13) #2 output shaft rear bearing preload 3.9-5.5 N·m (34-40 kgf·cm, 48-56 lbf-in).

Primary shaft assembly.

1) The radial runout of the input shaft (maximum) is 0.03 mm (0.0012 in.).

2) External diameter of input shaft:

2.1) Place of measurement A - 30.008–30.020 (1.1814–1.1819).

2.2) Place of measurement B - 32.002–32.018 (1.2599–1.2605).

3) Rear bearing shaft snap ring - A: 1.80-1.85 mm (0.0709-0.0728 in.); H: 1.85 - 1.90 mm (0.0728 - 0.0748 in); C: 1.90–1.95 mm (0.0748–0.0768 in); D: 1.95 - 2.00 mm (0.0768 - 0.0787 in); E: 2.00–2.05 mm (0.0787–0.0807 in); 0: 2.05 - 2.10 mm (0.0807 - 0.0827 in); 1: 2.10–2.15 mm (0.0827–0.0846 in); 2: 2.15–2.20 mm (0.0846–0.0866 in); 3: 2.20-2.25 mm (0.0866-0.0886 in); 4: 2.25–2.30 mm (0.0886–0.0906 in); 5: 2.30 - 2.35 mm (0.0906 - 0.0925 in); 6: 2.35–2.40 mm (0.09925–0.0945 in); F: 2.40 - 2.45 mm (0.0945 - 0.0965 in); G: 2.45 - 2.50 mm (0.0965 - 0.0984 in); H: 2.50–2.55 mm (0.0984–0.1004 in.).

Output shaft No. 1 assy.

1) 1st Drive Gear Axial Clearance Loaded - 0.10 to 0.35 mm (0.0039 to 0.0138 in.) nominal; maximum allowed 0.35 mm (0.0138 in.).

2) 2nd Drive Gear Axial Clearance Loaded - 0.11-0.46 mm (0.0043-0.018 in.) nominal; the maximum allowable is 0.46 mm (0.018 in.).

3) 3rd Drive Gear Axial Clearance Loaded - 0.11-0.54 mm (0.0043-0.0213 in.) nominal; the maximum allowable is 0.54 mm (0.0213 in.).

4) 4th Drive Gear Axial Clearance Loaded - 0.10-0.65 mm (0.0039-0.0256 in.) nominal; the maximum allowable is 0.65 mm (0.0256 in.).

5) 1st gear driven gear radial clearance - 0.015-0.68 mm (0.0006-0.0027 in.) nominal; maximum allowed 0.68 mm (0.0027 in.).

6) 2nd driven gear radial clearance - 0.015-0.048 mm (0.0006-0.0019 in.) nominal; maximum allowed 0.048 mm (0.0019 in.).

7) 3rd gear driven gear radial clearance - 0.015-0.066 mm (0.0006-0.0026 in.) nominal; maximum allowable 0.066 mm (0.0026 in.).

8) 4th driven gear radial clearance - 0.015-0.066 mm (0.0006-0.0026 in.) nominal; maximum allowable 0.066 mm (0.0026 in.).

9) #1 and #2 shift fork shaft outer diameter - nominal value 13.982-14.00 mm (0.5505-0.5512 in.); minimum allowed 13.982 mm (0.5505 in.).

10) #3 & #4 Shift Bar Outer Diameter - Nominal 0.5505" - 0.5512" (13.982-14.00mm); minimum allowed 13.982 mm (0.5505 in.).

11) No. 5 and No. 6 shift bar outer diameter - nominal value 13.982-14.00 mm (0.5505-0.5512 in.); minimum allowed 13.982 mm (0.5505 in.).   

12) Reverse fork shaft outer diameter - nominal 13.982-14.00 mm (0.5505-0.5512 in.); minimum allowed 13.982 mm (0.5505 in.).

13) #5 Shift Bar OD - Nominal 15.966-15.984 mm (0.6289-0.6293 in.); minimum allowed 15.966 mm (0.6289 in.).

14) Shift Fork #1 Inner Diameter and Thickness - 9.50-9.80 mm (0.3740-0.3858 in.) thick; inner diameter 14.010–14.043 mm (0.5516–0.5529 in).

15) Shift Fork #2 Inner Diameter and Thickness - 9.50-9.80 mm (0.3740-0.3858 in.) Thickness; inside diameter 14.010-14.043 mm (0.5516-0.5529 in.)/14.70-15.30 mm (0.5787-0.6024 in.).

16) Shift Fork #3 Inner Diameter and Thickness - 9.50-9.80mm (0.3740-0.3858 in.) Thickness; inner diameter 14.010–14.043 mm (0.5516–0.5529 in).

17) Inner diameter and thickness of the reverse gear fork - thickness 4.40-4.56 mm (0.1732-0.1795 in.); inner diameter 12.9-13.1 mm (0.5079-0.5157 in.)/14.70-15.30 mm (0.5787-0.6024 in.).

18) Shift Pivot #2 I.D. - Nominal 13.994 - 14.054 mm (0.5509 - 0.5533 in.); maximum 13.994–14.054 mm (0.5509–0.5533 in.).

19) #3 Shift Joint Inner Diameter - A Rating: 14.20-14.25mm (0.5591-0.5610 in.); Rating B: 15.994-16.054 mm (0.6297-0.6320 in); maximum A: 14.20–14.25 mm (0.5591–0.5610 in); maximum H: 15.994–16.054 mm (0.6297–0.6320 in.).

20) 1st Drive Gear I.D. - Nominal 53.015 - 53.040 mm (2.0872 - 2.0882 inches); maximum 53.040 mm (2.0882 inches).

21) 2nd Drive Gear I.D. - Nominal 56.015 - 56.030 mm (2.0872 - 2.0878 inches); maximum 56.030 mm (2.0878 inches).

22) 3rd Drive Gear I.D. - Nominal 42.015 - 42.040 mm (1.6541 - 1.6551 inches); maximum 42.040 mm (1.6551 inches).

23) 4th Drive Gear I.D. - Nominal 48.015 - 48.040 mm (1.8904 - 1.8913 inches); maximum 48.040 mm (1.8913 in.).

24) 1st Gear Synchronizer Lock Ring Clearance - 0.98 to 1.82 mm (0.039 to 0.072 in.) nominal; minimum 0.98 mm (0.039 in.).

25) 3rd Gear Synchronizer Lock Ring Clearance - 1.08-1.92 mm (0.043-0.076 in.) nominal; minimum 1.08 mm (0.043 in.).

26) 2nd Gear Synchronizer Lock Ring Clearance - 1.00-2.00 mm (0.039-0.079 in.) nominal; minimum 1.00 mm (0.039 in.).

27) 4th Drive Gear Synchronizer Lock Ring Clearance - 0.92-1.88 mm (0.036-0.074 in.) nominal; minimum 0.92 mm (0.036 in).

28) No. 1 Transmission Sliding Clutch Clearance 0.10-0.50 mm (0.0039-0.0197 in.).

29) No. 2 Transmission Sliding Clutch Clearance 0.10-0.50 mm (0.0039-0.0197 in.).

Output shaft No. 2 assy.

1) No. 2 output shaft runout (maximum) - 0.03 mm (0.0012 in.).

2) Outer diameter of output shaft No. 2 - measuring point A: 32.002 - 32.018 (1.2599 - 1.2605): measuring point B: 35.984 - 36.000 (1.4167 - 1.4173); place of measurement C: 41.984–42.000 (1.6529–1.6535); place of measurement D: 46.984–47.000 (1.8498–1.8504); place of measurement E: 35.002–35.018 (1.3780–1.3787).

3) 5th driven gear axial clearance under load - 0.10-0.55 mm (0.0039-0.0217 in.) nominal; maximum allowed 0.55 mm (0.0217 in.).

4) 6th Drive Gear Axial Clearance Loaded - 0.10-0.55 mm (0.0039-0.0217 in.) nominal; maximum allowed 0.55 mm (0.0217 in.).

5) Axial clearance of reverse driven gear - nominal value 0.11-0.34 mm (0.0043-0.0134 in.); maximum allowed 0.34 mm (0.0134 in.).

6) 5th driven gear radial clearance - 0.015-0.066 mm (0.0006-0.0026 in.) nominal; maximum allowable 0.066 mm (0.0026 in.).

7) 6th driven gear radial clearance - 0.015-0.066 mm (0.0006-0.0026 in.) nominal; maximum allowable 0.066 mm (0.0026 in.).

8) Radial clearance of reverse driven gear - nominal value 0.015 - 0.068 mm (0.0006 - 0.0027 in.); maximum allowed 0.068 mm (0.0027 in.).

9) 5th Drive Gear I.D. - Nominal 48.015 - 48.040 mm (1.8904 - 1.8913 inches); maximum allowed 48.0404 mm (1.8913 inches).

10) 6th Drive Gear I.D. - Nominal 42.015 - 42.040 mm (1.6541 - 1.6551 inches); maximum allowed 42.040 mm (1.6551 inches).

11) Reverse driven gear I.D. - Nominal 53.015 - 53.040 mm (2.0872 - 2.0882 in.); maximum allowed 53.040 mm (2.0882 inches).

12) 5th gear synchroniser ring clearance - 0.80-1.60 mm (0.031-0.063 in.) nominal; minimum 0.80 mm (0.031 in.).

13) 6th Gear Synchronizer Lock Ring Clearance - 0.80-1.60 mm (0.031-0.063 in.) nominal; minimum 0.80 mm (0.031 in.).  

14) Reverse synchroniser ring clearance - 0.68 to 1.32 mm (0.027 to 0.052 in.) nominal; minimum 0.68 mm (0.027 in.).

15) No. 3 Transmission Sliding Clutch Clearance 0.10-0.50 mm (0.039-0.0197 in.).

16) No. 4 transmission sliding clutch clearance is 0.15-0.41 mm (0.059-0.0161 in.).

17) Reverse Hub Shaft Snap Ring - A: 2.25-2.30mm (0.0886-0.0906 in.); H: 2.30 - 2.35 mm (0.0906 - 0.0925 in); C: 2.35–2.40 mm (0.0925–0.0945 in); D: 2.40 - 2.45 mm (0.0945 - 0.0965 in); E: 2.45–2.50 mm (0.0965–0.0984 in); F: 2.50 - 2.55 mm (0.0984 - 0.1004 in); G: 2.55 - 2.60 mm (0.1004 - 0.1024 inches); H: 2.60–2.65 mm (0.1024–0.1043 in.).

18) No. 3 - 1 transmission hub shaft snap ring: 2.25-2.30 mm (0.0886-0.0906 in.); 2: 2.30–2.35 mm (0.0906–0.0925 in); 3: 2.35–2.40 mm (0.0925–0.0945 in); 4: 2.40–2.45 mm (0.0945–0.0965 in); 5: 2.45-2.50 mm (0.0965-0.0984 in); 6: 2.60–2.55 mm (0.0984–0.1004 in.).

19) #2 Output Snap Ring - B: 1.85-1.90 mm (0.0728-0.0748 in.); C: 1.90–1.95 mm (0.0748–0.0768 in); D: 1.95 - 2.00 mm (0.0768 - 0.0787 in); E: 2.00–2.05 mm (0.0787–0.0807 in); 0: 2.05 - 2.10 mm (0.0807 - 0.0827 in); 1: 2.10–2.15 mm (0.0827–0.0846 in); 2: 2.15–2.20 mm (0.0846–0.0866 in.).

20) Output Shaft Snap Ring - A: 2.25-2.30 mm (0.0886-0.0906 in.); H: 2.30 - 2.35 mm (0.0906 - 0.0925 in); C: 2.35–2.40 mm (0.0925–0.0945 in); D: 2.40 - 2.45 mm (0.0945 - 0.0965 in); E: 2.45–2.50 mm (0.0965–0.0984 in); F: 2.50 - 2.55 mm (0.0984 - 0.1004 in); G: 2.55 - 2.60 mm (0.1004 - 0.1024 inches); H: 2.60–2.65 mm (0.1024–0.1043 in.).

21) No. 2 - 1 Transmission Slip Hub Hub Snap Ring: 2.25-2.30 mm (0.0886-0.0906 in.); 2: 2.30–2.35 mm (0.0906–0.0925 in); 3: 2.35–2.40 mm (0.0925–0.0945 in); 4: 2.40–2.45 mm (0.0945–0.0965 in); 5: 2.45-2.50 mm (0.0965-0.0984 in); 6: 2.50–2.55 mm (0.0984–0.1004 in.).

22) Output Shaft Bearing Snap Ring - H: 1.85 - 1.90 mm (0.0728 - 0.0748 in.); C: 1.90–1.95 mm (0.0748–0.0768 in); D: 1.95 - 2.00 mm (0.0768 - 0.07871 in); E: 2.00–2.05 mm (0.0787–0.0807 in); 0: 2.05 - 2.10 mm (0.0807 - 0.0827 in); 1: 2.10–2.15 mm (0.0827–0.0846 in); 2: 2.15–2.20 mm (0.0846–0.0866 in.).

Gear lever shaft.

1) The installation depth of the shift bar bearing is 1.0 to 1.5 mm (0.0393 to 0.0590 in.).

2) The installation depth of the drive shaft cover oil seal is 0–0.5 mm (0–0.020 in.).

3) Insertion depth of #1 inner shift lever split pin is 0.4-1.4mm (0.0157-0.0551 inch).

differential case.

1) The nominal circumferential clearance of the front differential side gear is 0.05 to 0.20 mm (0.0020 to 0.0079 in.).

2) Side gear thrust washer - 1.23-1.27 (0.0484-0.0500 in.); 1.28–1.32 (0.0504–0.0520 in); 1.33–1.37 (0.0524–0.0539 in); 1.38–1.42 (0.0543–0.0559 in); 1.43–1.47 (0.0583–0.0579 in); 1.48–1.52 (0.0583–0.0598 in); 1.53–1.57 (0.0602–0.0618 in); 1.58–1.62 (0.0622–0.0638 in); 1.63–1.67 (0.0642–0.0657 in); 1.68–1.72 (0.0661–0.0677 in); 1.73–1.77 mm (0.0681–0.0697 in); 1.78–1.82 mm (0.0701–0.0717 in); 1.83–1.87 mm (0.0720–0.0736 in); 1.88–1.92 mm (0.0740–0.0756 in); 1.93–1.97 mm (0.0760–0.0776 in.).

3) The thickness of the front differential pinion thrust washer (minimum allowable) is 0.54-0.66 mm (0.0213-0.0260 in.).

4) #1 Front Differential Pinion Shaft - Minimum Diameter 20.31-20.52 mm (0.7996-0.8079 in.).

Source:  TOYOTA RAV4 Multimedia Maintenance and Repair Manual since 2006. release