The habitual intercuspation is used ubiquitous for manufacturing small dental restorations. However, a little is known on its precision. The aim of the present study was therefore to investigate the unambiguity and accuracy of the habitual occlusion in mounted plaster casts from fully dentate persons. Eighty-one fully dentate volunteers, 36 women and 45 men aged 26.8 +/- 6.2 years (18-55 years), with minor fillings and no signs or symptoms of TMD took part in the experiments. Silicone impressions were taken, poured with stone plaster and the obtained casts mounted into Dentatus ARL(R)- articulators using an individual face bow transfer. Subsequently, the models were transferred to a custom-made measuring articulator where the lateral leeway and the accuracy of the hand-held habitual intercuspation were quantified in the condylar area. Measurements were repeated seven times with the upper cast pushed either to the maximum right or the maximum left intercuspation. The hand-held habitual intercuspation of upper and lower cast proved ambiguous in 57% of pairs of casts. The average lateral leeway of the habitual intercuspation in the condylar area was 0.10 +/- 0.05 mm (0-0.51 mm; median 0.07 mm) between the maximum right and left occlusal positions. The average accuracy of three repeated measurements was 0.22 +/- 0.09 mm (0.02-1.17 mm; median 0.16 mm). Natural occlusal surfaces in a full dentition do not guarantee an unambiguous habitual intercuspation of the plaster casts. The described leeway and technical limits might be possible causes for occlusal adjustments that are sometimes necessary when inserting restorations manufactured in habitual intercuspation.