07 - Tfmua We 0431

WORKSHOP MANUAL
TF SERIES
MANUAL TRANSMISSION
(MUA MODELS)
SECTION 7B1
MANUAL TRANSMISSION
7B1-1
SECTION 7B1 MANUAL TRANSMISSION MUA CONTENTS

PAGE
TRANSMISSION
MUA (4 2)
Service Precaution .......................................................................................................... 7B1 3 General Description ........................................................................................................ 7B1 4 Rear Oil Seal (4 2) ........................................................................................................... 7B1 5 Transmission (4 2) ......................................................................................................... 7B1 7 Disassembled View..................................................................................................... 7B1 7 Removal ....................................................................................................................... 7B1 8 Installation ................................................................................................................... 7B1 12 Transmission Case .......................................................................................................... 7B1 18 Major Component ........................................................................................................ 7B1 18 Disassembly ................................................................................................................ 7B1 19 Reassembly ................................................................................................................. 7B1 20 Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and Interlock Pin ........................................................................................................... 7B1 23 Disassembled View..................................................................................................... 7B1 23 Disassembly ................................................................................................................ 7B1 24 Inspection and Repair................................................................................................. 7B1 25 Reassembly ................................................................................................................. 7B1 26 Reverse Gear and 5th Gear ............................................................................................ 7B1 27 Disassembled View..................................................................................................... 7B1 27 Disassembly ................................................................................................................ 7B1 29 Inspection and Repair................................................................................................. 7B1 31 Reassembly ................................................................................................................. 7B1 31 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 38 Disassembled View..................................................................................................... 7B1 38 Disassembly ................................................................................................................ 7B1 40 Inspection and Repair................................................................................................. 7B1 42 Reassembly ................................................................................................................. 7B1 45 Main Data and Specifications ......................................................................................... 7B1 51
7B1-2
MANUAL TRANSMISSION
Troubleshooting............................................................................................................... 7B1 55 Special Tools (4 2) .......................................................................................................... 7B1 62
MUA (4 4)
Service Precaution .......................................................................................................... 7B1 63 General Description ........................................................................................................ 7B1 64 Transmission (4 4) ......................................................................................................... 7B1 65 Disassembled View..................................................................................................... 7B1 65 Removal ....................................................................................................................... 7B1 66 Installation ................................................................................................................... 7B1 70 Transmission Case .......................................................................................................... 7B1 77 Major Component ........................................................................................................ 7B1 77 Disassembly ................................................................................................................ 7B1 78 Reassembly ................................................................................................................. 7B1 79 Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and Interlock Pin ........................................................................................................... 7B1 82 Disassembled View..................................................................................................... 7B1 82 Disassembly ................................................................................................................ 7B1 83 Inspection and Repair................................................................................................. 7B1 83 Reassembly ................................................................................................................. 7B1 84 Reverse Gear and 5th Gear ............................................................................................ 7B1 85 Disassembled View..................................................................................................... 7B1 85 Disassembly ................................................................................................................ 7B1 86 Inspection and Repair................................................................................................. 7B1 88 Reassembly ................................................................................................................. 7B1 88 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 94 Disassembled View..................................................................................................... 7B1 94 Disassembly ................................................................................................................ 7B1 96 Inspection and Repair.............................................................................................. 7B1 98 Reassembly .............................................................................................................. 7B1 101 Main Data and Specifications ..................................................................................... 7B1 107 Troubleshooting ........................................................................................................... 7B1 111 Special Tools (4 4) ...................................................................................................... 7B1 118
MANUAL TRANSMISSION
7B1-3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
7B1-4
MANUAL TRANSMISSION
General Description
MUA Transmission (4 2)
A07R300006
The MUA is a constant mesh transmission, synchronized in all speeds. The transmission has been designed to provide low shift effort and low gear noise.
Principle parts of the transmission are the integral clutch housing, the intermediate plate, the rear cover, and the gears. The transmission control box is built into the transmission.
MANUAL TRANSMISSION
7B1-5
Rear Oil Seal (4 2)

Disassembled View
220R300030
Legend (1) Rear Propeller Shaft
(2) Rear Oil Seal
Removal
1. Raise and support vehicle with suitable jack stands. 2. Remove propeller shaft flange yoke bolts and nuts at the differential side. 3. Remove center bearing from crossmenber. 4. Remove prepeller shaft from the transmission main shaft spline. Refre to the section Rear Propeller Shaft. 5. Use a screwdriver to pry the rear oil seal from the rear cover.
Installation
1. Install a new oil seal (2) using the installer 5-85220050-0.
220RS044
2. Insert the splined yoke into the transimission mainshaft spline. 3. Install the propeller shaft flange yoke to the drive pinion flange.
7B1-6
MANUAL TRANSMISSION
Torque : 63 Nm (6.4 kgm/46 lbft) 4. Install center bearing on crossmember. Torque : 69 Nm (7.0 kgm/51 lbft) 5. Check transmission fluid level. 6. Lower vehicle.
MANUAL TRANSMISSION
7B1-7
Transmission (4 2)
Disassembled View
RTW47BLF000701
Legend (1) Gear Control Lever Knob (2) Rear Floor Console (bucket seat) (3) Front Floor Console (4) Grommet Assembly (5) Gear Control Lever (6) Rear Propeller Shaft (7) Exhaust Pipe Nut (Diesel engine only) (8) Exhaust Pipe (6VE1 only) (9) Fuel Pipe Bracket
(10) Slave Cylinder (11) Nut : rear mount to Crossmember (12) Transmission Crossmember (13) Nut : rear mount to transmission (14) Rear Mount Rubber (15) Starter (Diesel engine only) (16) Transmission Retaining Nut and Bolt (17) Transmission Assembly
7B1-8
MANUAL TRANSMISSION 5. Remove grommet assembly (4).
Removal
1. Disconnect battery ground cable. 2. Remove gear control lever knob (1). 3. Remove rear floor console (2). (Bucket seat) Refer to the section Floor Console. 4. Remove front floor console (3). Refer to the section Floor Console.
745R300006
Legend (1) Knob (2) Rear Floor Console (3) Front Floor Console
RTW47BMH000101
MANUAL TRANSMISSION 6. Remove gear control lever (5). 7. Raise and support vehicle with suitable stands. 8. Remove rear propeller shaft (6). NOTE: Apply alignment marks on the flange at the differential side. 10. Remove the exhaust pipe (8). (6VE1 only)
7B1-9
RTW37ASH0001
11. Disconnect harness connectors and clips on the transmission. Neutral Switch Back up Switch
401RS023
Car Speed Sensor 12. Remove the fuel pipe bracket (9) with pipes from the transmission (17).
9. Loosen the front exhaust pipe fixing nuts (7) at the engine side but not remove them. (Diesel engine only)
Diesel engine
220R300012 150R300003
Legend (1) Bolt (2) Nut (3) Fuel Pipe Assembly
7B1-10
MANUAL TRANSMISSION 14. Support transmission with a transmission jack.
6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it.
220RS001
Diesel engine
15. Remove engine rear mount nuts (11) fixing on cross member from transmission crossmember (12). 16. Remove engine rear mount nuts (13) fixing on transmission.
220LV019
6VE1
220R300029
Legend (1) Transmission (2) Nut : rear mount to transmission (3) Rear Mount Rubber (4) Nut : rear mount to crossmember (5) Transmission Crossmember
206RW002
MANUAL TRANSMISSION 17. Remove the middle part of transmission crossmember (12) by removing four fixing bolts and nuts.
7B1-11
20. Use the clutch release bearing remover 5-88402291-0 (J-39207) to disconnect the clutch release bearing from the clutch pressure plate. (6VE1 only)
501R300008
220RW109
18. Take out the rear mount rubber (14). 19. Remove starter (15) (Diesel engine only).
Release bearing disconnection 1. Pull the shift fork toward the transmission to press the clutch release bearing against the clutch. 2. Insert the clutch release bearing remover between the wedge collar and the release bearing. 3. Turn the remover to separate the release bearing.
060L100070
7B1-12
MANUAL TRANSMISSION
NOTE: Be sure not to insert the remover between the wedge collar and the clutch.
220RW019
Legend (1) Pressure Plate Assembly (2) Release Bearing (3) Wedge Collar
21. Remove transmission retaining nuts and bolts(16). Remove transmission assembly (17) from the vehicle.
Installation
220RW063
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline. 2. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same. 3. Align the top gear shaft spline with the clutch driven plate spline.
220RW064
MANUAL TRANSMISSION 4. Install the transmission assembly (17) to the engine. Tighten the transmission nuts and bolts (16) as shown in the figure. Diesel engine
7B1-13
RTW37BLF000901
7B1-14 6VE1
MANUAL TRANSMISSION
RTW37BLF0001
MANUAL TRANSMISSION C24NE
7B1-15
RTW37BLF0002
5. Apply a force of about 113N (26 Ib) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing. (6VE1 only) NOTE: A clicking sound is heard when the release bearing and the tip of the diaphragm spring engage each other. Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine while applying a force of about 25 N (5.5 lb). If the shift fork will not move, then they are securely engaged.
220RS006
7B1-16
MANUAL TRANSMISSION
6VE1, C24NE
6. Install starter(15). (Diesel engine only) NOTE: Tighten the lower bolt temporarily. After installing the fuel pipe assembly, tighten the bolt to the specified torque. Torque: 76 N+m (7.7 kg+m/56 lb+ft) 7. Install the rear support rubber (14) on the transmission and tighten the nuts to the specified torque. Torque: 52 N+m (5.3 kg+m/38 lb+ft) 8. Install the middle part of transmission crossmember (12) and bolts. Tighten the nuts to the specified torque. Torque: 67 N+m (6.8 kg+m/49 lb+ft) 9. Install engine rear mount nuts (11) fixing on transmission crossmember (12). Torque: 52 N+m (5.3 kg+m/38 lb+ft) Remove the transmission jack from transmission side. 10. Apply grease to top hole portion of the shift fork. Install slave cylinder (10) and tighten the bolts to the specified torque. Torque: 76 N+m (7.7 kg+m/56 lb+ft) 11. Install the fuel pipe brackets (9) on the transmission. Install the fuel pipe assembly to the fuel brackets. Torque: Bolt & Nut Nut 76 N+m (7.7 kg+m/56 lb+ft) 37 N+m (3.8 kg+m/28 lb+ft)
Scan-1
12. Connect transmission harness connectors and clip. Connector: neutral switch, car speed sensor, and backup switch. 13. Tighten exhaust pipe fixing nuts (7) to the specified torque. (Diesel engine only) Torque: 67 N+m (6.8 kg+m/49 lb+ft)
Diesel engine
150R300003
220R300012
MANUAL TRANSMISSION 14. Install the exhaust pipe (8). (6VE1) Torque: 67 N+m (6.8 kg+m/49 lb+ft)
7B1-17
RTW37ASH000101
15. Install rear propeller shaft (6). Torque: 63 N+m (6.4 kg+m/46 lb+ft) 16. Install center bearing on crossemember. Torque: 69 N+m (7.0 kg+m/51 lb+ft) 17. Install gear control lever (5). Torque: 19 N+m (1.9 kg+m/14 lb+ft) 18. Install grommet assembly (4). Torque: Screw Nut 1.4 N+m (0.14 kg+m/12 lb+in) 7 N+m (0.7 kg+m/61 lb+in)
RTW47BMH000101
Legend (1) Grommet Assembly (2) Floor Panel (3) Front
19. Install front floor console (3) and rear floor console (2). 20. Install gear control lever knob (1). To the female thread portion, adhesive (TB1344 or LOCTITE 222 or equiv.) of 3 - 4 drops to be applied and transmission knob tightened. Torque: 9 N+m (0.9 kg+m/78 lb+in) After tightening to specified torque, knob rewrenched until direction of shift pattern due positioned. 21. Connect battery ground cable.
7B1-18
MANUAL TRANSMISSION
Transmission Case
Major Component
RTW37BLF0005
Legend (1) Gear Control Box Assembly and Gasket (2) Speedometer Sensor and Driven Gear (3) Rear Cover Assembly (4) Intermediate Plate with Gear Assembly (5) Transmission Case (6) Release Bearing (with Spring) : Diesel engine (7) Shift Fork : Diesel engine (8) Counter Front Bearing Snap Ring
(9) Front Cover (with Oil Seal) (10) Top Gear Bearing Snap Ring (11) Release Bearing : C24NE (12) Shift Fork : C24NE (13) Fulcrum Bridge : 6VE1 (14) Release Bearing : 6VE1 (15) Shift Fork : 6VE1
MANUAL TRANSMISSION
7B1-19
Disassembly
1. Clean the exterior of the unit with solvent. 2. Remove the drain plug from the transmission case and drain the lubricant. 3. Remove the clutch release bearing with spring (6)(11) from the transmission case. 4. Remove the shift fork (7)(12), and boot. (Diesel engine, C24NE) 5. Remove the shift fork snap pin. (6VE1) 6. Remove the shift fork pin and shift fork from the fulcrum bridge. (6VE1)
7. Remove the fulcrum bridge from the transmission case. (6VE1)
RTW37ASH0002
Legend (1) Fulcrum bridge
8. Remove the front cover (9) and gasket from the transmission case. 9. Remove snap ring (8) fixing counter front bearing. 10. Use a pair of snap ring pliers to remove the snap ring (10) fixing top gear bearing.
RTW47BSH000601
Legend (1) Shift fork pin (2) Shift fork (3) Release bearing
226RS001
11. Remove the speedometer sensor (2). Remove the plate (2). Remove the driven gear bushing and driven gear (2). NOTE : Apply a reference mark to the driven gear bushing before removal. 12. Remove gear control box assembly (1).
7B1-20
MANUAL TRANSMISSION 4. Install a new gasket and gear control box assembly (1). Install the harness clips and brackets and then tighten four new gear control box bolts to the specified torque. Torque: 20 N+m (2.0 kg+m/14 lb+ft)
13. Remove the rear cover assembly (3) from the transmission case (5) and intermediate plate (4). 14. Remove intermediate plate with gear assembly (4) from transmission case (5).
Reassembly
1. Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transmission case (5), intermediate plate (4) and rear cover (3) fitting surfaces. 2. Install the intermediate plate with gear assembly (4) to the transmission case (5). Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face. Avoid subjecting the main shaft to sudden shock or stress. 3. Install the rear cover with oil seal (3) on the intermediate plate with gear (4) by performing the following steps. Cover the shaft splines with adhesive tape. This will prevent damage to the oil seal lip.
261R300004
5. Install the O-ring (4) to the speedometer driven gear bushing (3). Install the driven gear to the speedometer driven gear bushing (3). 6. Install the speedometer driven gear assembly (2) to the transmission rear cover (3). Install the plate (1) to the transmission rear cover (3). Torque: 15 N+m (1.5 kg+m/11 lb+ft)
MANUAL TRANSMISSION 7. Install the speedometer sensor (2). Torque: 27 N+m (2.8 kg+m/20 lb+ft)
7B1-21
Use the oil seal installer 5-8840-0026-0 to install the oil seal to the front cover.
220R3000020
225R300001
8. Install top gear bearing snap ring (10) and counter front bearing snap ring (8). Use a pair of snap ring pliers to install the snap rings to the mainshaft and countershaft. The snap rings must be fully inserted into the bearing snap ring groove. 9. Front cover with oil seal (9). Front Cover Oil Seal Replacement Remove the oil seal from the front cover. Apply engine oil to a new oil seal outer circumference. Apply recommended grease to the oil seal lip.
10. Install a new gasket and front cover (9) to the transmission case. NOTE: Take care not to damage the oil seal. Notes When Tightening the Bolt: After cleaning the bolt hole, dry it thoroughly with air. After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent before tightening it. Tighten six front cover bolts to the specified torque. Torque: 25 N+m (2.6 kg+m/19 lb+ft) 11. Apply molybdenum disulfide type grease to the areas as shown in the figure and install shift fork (7). (Diesel engine, C24NE)
F07L100026
7B1-22
MANUAL TRANSMISSION 15. Install the washer and snap pin. (6VE1)
12. Install the fulcrum bridge to the transmission case. (6VE1) Torque: 38 N+m (3.9 kg+m/28 lb+ft)
RTW37ASH0002
13. Apply molybdenum disulfide type grease to the pin hole inner circumferences and thrust surfaces. (6VE1) 14. Attach the shift fork to the fulcrum bridge and insert the pin from below of the fulcrum bridge. (6VE1)
RTW47BMH000201
16. Pack the inside recess (A) and coat the back (B) of the release bearing with molybdenum disulfide type grease as shown in the figure.
A07RW075
17. Install the release bearing (6) on the front cover, joining it to the shift frok.
MANUAL TRANSMISSION
7B1-23
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and Interlock Pin
Disassembled View
RTW47BLF000501
Legend (1) Detent Spring Plate and Gasket (2) Detent Spring (3) Detent Ball (4) Spring (5) Rev-5th Shift Rod (6) Rev-5th Shift Arm and Reverse Inhibitor
(7) 1st-2nd Shift Rod (8) 3rd-4th Shift Rod (9) 3rd-4th Shift Arm (10) 1st-2nd Shift Arm (11) Interlock Pin (12) Intermediate Plate and Gear Assembly
7B1-24
MANUAL TRANSMISSION
Disassembly
1. Remove detent spring plate and gasket (1), detent spring (2) and detent ball (3). Use a magnetic hand to remove the detent balls from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when pulling out the shift rod rearward. Interlock pins are located between the shifter rods in the intermediate plate.
220RS011
2. Remove spring (4). 3. Remove rev-5th shift rod (5), and rev-5th shift arm and reverse inhibitor (6). Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8), 3rd-4th shift arm (9), and 1st-2nd shift arm (10). Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift rods carefully. 4. Remove interlock pin (11) from intermediate plate and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift arm spring pins from the shift arms and the shift rods.
MANUAL TRANSMISSION
7B1-25
Inspection and Repair

Make the necessary adjustments, and part replacements if excessive wear or damage is discovered during inspection.
Shift Arm Thickness

Use a micrometer to measure the shift arm thickness. If the measured value is less than the specified limit, the shift arm must be replaced.
Shift Arm Thickness Standard 9.60 - 9.85 mm 1st-2nd (0.378 - 0.388 in) 3rd-4th 9.60 - 9.80 mm Rev.5th (0.378 - 0.386 in)
Limit 9.0 mm (0.354 in)
220RS012
Detent Spring Tension

Use a spring tester to measure the detent spring tension. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring Tension Compressed height 20 mm (0.787 in) Standard 87.2 - 97.1 N (19.6 - 21.8 lb)
230RS006
Detent Spring Free Length

Use a vernier caliper to measure the detent spring free length. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring Free Length Standard 26.8 mm (1.06 in)
Limit 26.2 mm (1.03 in)

220RS013
SOUTH AFRICA 5th-Rev Only Detent Spring Free Length Standard Outer 27.6 mm (1.09 in) Inner 26.6 mm (1.05 in)
Limit 27.0 mm (1.06 in) 26.0 mm (1.02 in)
SOUTH AFRICA 5th-RV Only Detent Spring Free Length Compressed Outer Inner 20 mm (0.787 in) 20 mm (0.787 in)
Standard 93.5 103.3 N (21.0 23.3 lb) 26.4 36.3 N (5.9 8.2 lb)
7B1-26
MANUAL TRANSMISSION 4. Install spring (4). 5. Put detent balls (3) in the intermediate plate holes. Apply oil to the detent balls. 6. Install detent springs (2) and detent spring plate and gasket (1). Install a new gasket and the detent spring plate. Tighten the detent spring plate bolts to the specified torque. Torque: 25 N+m (2.5 kg+m/18 lb+ft)
Reassembly
1. Install rev-5th shift arm and reverse inhibitor (6) and rev-5th shift rod (5). Apply oil to the reverse inhibitor inner surface. Install the shift rod in the intermediate plate (12). Hold a round bar against the shift rod end lower face to protect it against damage. Install a new spring pin. Never reinstall the used spring pin. Install the interlock pin (11) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate (12). 2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9) to intermediate plate and gear assembly (12). 3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7). Install the interlock pin (11) in the intermediate plate and gear assembly (12). Install the 3rd-4th shift rod (8) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate. Install the interlock pin (11) and then 1st-2nd shift rod (7) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate. Hold a round bar against the shift rod end lower face to protect it against damage. Install a new spring pin. Never reinstall the used spring pin.
220RS030
Legend (1) Warped
230RS007
MANUAL TRANSMISSION
7B1-27
Reverse Gear and 5th Gear

Disassembled View
226R300027
Legend (1) Bearing Snap Ring (2) Ball Bearing (3) Bearing Snap Ring (4) Speedometer Drive Gear (5) Clip (6) Retainer Snap Ring (7) Retainer (8) Thrust Plate (9) Thrust Washer and Lock Ball (10) Reverse Idler Gear Snap Ring
(11) Reverse Idler Gear Assembly (12) Idle Shaft Pin (13) Thrust Washer (14) Reverse Idler Gear (15) Reverse Idler Shaft (16) Bearing Snap Ring (17) Ball Bearing (18) Counter 5th Gear (19) Counter Reverse Gear (20) 5th Gear
7B1-28
MANUAL TRANSMISSION (26) Reverse Gear (27) Needle Baring (28) Bearing Plate and Screw (29) Bearing Snap Ring (30) Intermediate Plate
(21) 5th Block Ring (22) Needle Bearing (23) Mainshaft Nut (24) Rev-5th Synchronizer Assembly (25) Reverse Block Ring
MANUAL TRANSMISSION
7B1-29
Disassembly
1. Use a pair of snap ring pliers to remove the bearing snap ring (1). 2. Set the bearing remover 5-8840-2155-0 and puller 5-8840-2027-0 to the bearing (2) and the mainshaft end to remove the ball bearing (2).
6. Remove the reverse idler gear assembly (11) from the intermediate plate (30).
226RS005
262L100001
3. Remove the bearing snap ring (3), clip (5), speedometer drive gear (4), retainer snap ring (6) and retainer (7). 4. Remove thrust plate (8) and thrust washer and lock ball (9). 5. Use a pair of snap ring pliers to remove reverse idler gear snap ring (10).
7. Remove idle shaft pin (12), thrust washer (13), reverse idler gear (14), and reverse idler shaft (15). 8. Use a pair of snap ring pliers to remove the snap ring (16). 9. Attach a universal puller to the counter gear shaft. Use a universal puller to remove the ball bearing (17) and the counter 5th gear (18).
226RS006
10. Remove counter reverse gear (19).
226RS004
7B1-30
MANUAL TRANSMISSION
11. Remove 5th gear (20), 5th block ring (21), and needle bearing (2 piece type) (22).
226RW210
226RS007
Use the mainshaft nut wrench 5-8840-2156-0 to remove the mainshaft nut (23).
12. Remove the mainshaft nut (23) according to following steps. Attach the holding fixture 5-8840-2160-0 and base 5-8840-0003-0 to the mainshaft and the counter gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd gear. Engage the 1st-2nd synchronizer with the 1st gear.
MANUAL TRANSMISSION 13. Use screw drivers between the reverse gear (26) and bearing plate (28) to remove the Rev-5th synchronizer assembly (24) together with reverse block ring (25) and reverse gear (26).
7B1-31
226RS011
17. Hold the snap ring open with the pliers. Push the intermediate plate (30) toward the rear of the transmission to remove it.
226RS010
14. Remove needle bearing (27). 15. Use the torx bit wrench (T45) 5-8840-0047-0 to remove the bearing plate and screw(28) from the intermediate plate.
The bearing snap ring (29) will come free.

Refer to Top Gear Shaft, Main Gear Shaft, and Counter Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly. Set the holding fixture 5-8840-2160-0 to the mainshaft and the counter gear and then install it on the base 5-8840-0003-0. Install the intermediate plate (30) on the gear assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft bearing snap ring (2) (29).
226RW212
7B1-32
MANUAL TRANSMISSION 5. Assemble rev-5th synchronizer assembly (24) by performing the following steps. 1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the outer circumference. 2. Check that the inserts (3) fit snugly into the clutch hub (5) ring insert grooves. 3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration. 4. Check that the clutch hub (5) and the sleeve (6) slide smoothly. 5. Install the synchronizer assembly (24) to the mainshaft. The clutch hub face with the heavy boss must be facing the reverse gear side.
2. Install bearing snap ring (29). 3. Apply recommended thread locking agents (LOCTITE 242) or its equivalent to each of the bearing plate screw threads. Install bearing plate and screw (28). Tighten the screws to the specified torque by using torx bit wrench 5-8840-0047-0. Torque: 15 N+m (1.5 kg+m/11 lb+ft)
220RW137
4. Install needle bearing (27), reverse gear (26), and reverse block ring (25).
226RS013
226RS049
MANUAL TRANSMISSION 6. Mesh the 1st-2nd and 3rd-4th synchronizers with both the 1st and 3rd gears (double engagement). 8. Use a punch to stake the mainshaft nut (23).
7B1-33
226RW153 226RS015
This will prevent the mainshaft from turning. 7. Install the new mainshaft hub nut. Use the mainshaft nut wrench 5-8840-2156-0 to tighten the mainshaft nut (23) to the specified torque. Torque: 137 N+m (14 kg+m/101 lb+ft)
9. Install needle bearing (22), 5th block ring (21), and 5th gear (20). 10. Apply engine oil to the counter reverse gear (19) and the reverse gear (26). Install the counter reverse gear (19) to the counter shaft. The reverse gear projection must be facing the intermediate plate.
226RW214 226RW151
7B1-34
MANUAL TRANSMISSION There are six snap ring sizes available. The snap rings are color&dash;coded to indicate their thickness.
11. Install the counter 5th gear (18) to the counter shaft.
226RS019
12. Install ball bearing (17) and bearing snap ring (16) by performing the following steps: Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.
226RS021
Ball Bearing and Snap Ring Clearance Standard: 0 - 0.15 mm (0 - 0.0059 in) Snap Ring Availability Thickness Color Coding 1.1 mm (0.043 in) White 1.2 mm (0.047 in) Yellow 1.3 mm (0.051 in) Blue 1.4 mm (0.055 in) Pink 1.5 mm (0.059 in) Green 1.6 mm (0.063 in) Brown Use a pair of snap ring pliers to install the snap ring(13) to the counter gear shaft. The snap ring must be fully inserted into the counter gear shaft snap ring groove. 13. Assemble reverse idler shaft (15), reverse idler gear (14), thrust washer (13), and idle shaft pin (12) into reverse idler gear assembly (11). The trust washer should be assembled as oil groove faces to gear side.
226RS020
MANUAL TRANSMISSION 14. Select reverse idler gear snap ring (10) which will provide the minimum clearance between the intermediate plate (30) and the snap ring (10).
7B1-35
Use a pair of snap ring pliers to install the snap ring to the reverse idler shaft. The snap ring must be fully inserted into the reverse idler shaft snap ring groove. 15. Install thrust washer and lock ball (9) by performing the following steps: Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer. 5th Gear and Thrust Washer Clearance Standard: 0.10 - 0.25 mm (0.004 - 0.010 in)) Measure clearance "A" as shown in the figure.
226RS022
There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness. Intermediate Plate and Snap Ring Clearance Standard: 0 - 0.15 mm (0 - 0.0059 in) Snap Ring Availability Thickness Color Coding 1.2 mm (0.047 in) White 1.3 mm (0.051 in) Yellow 1.4 mm (0.055 in) Blue
226RS023
Select appropriate thrust washer from chart. There are four thrust washer sizes available. Thrust Washer Availability Thickness Color Clearance A mm (in) mm (in) Coding mm (in) 8.05 - 8.1 0.15 - 0.25 7.9 (0.311) White (0.317-0.319) (0.006-0.010) 8.1 - 8.2 0.1 - 0.25 8.0 (0.315) Yellow (0.319-0.323) (0.004-0.010) 8.2 - 8.3 0.1 - 0.25 8.1 (0.319) Green (0.323-0.327) (0.004-0.010) 8.3 - 8.36 0.1 - 0.21 8.2 (0.323) Blue (0.327-0.329) (0.004-0.008) The thrust washers are color coded to indicate their thickness as shown in the figure.
226RS021
7B1-36
MANUAL TRANSMISSION 19. Install the bearing snap ring (1).
226RS024
Apply grease to the thrust washer and the lock ball. Install the thrust washer and the lock ball. 16. Install thrust plate (8) and retainer (7). 17. Install the retainer snap ring (6), clip (5), speedometer drive gear (4) and bearing snap ring (3). 18. Apply engine oil to the bearing (2) inner and outer circumference. Use the installer 5-8840-2159-0 to install the ball bearing (2) to the mainshaft.
226L100002
MANUAL TRANSMISSION
7B1-37
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
7B1-38
MANUAL TRANSMISSION
Legend (1) Top Gear Shaft Snap Ring (2) Top Gear Shaft (3) Ball Bearing (4) Needle Bearing (5) Top Block Ring (6) Mainshaft Snap Ring (7) 3rd-4th Synchronizer Assembly (8) 3rd Block Ring (9) 3rd Gear (10) Needle Bearing (11) Needle Bearing Collar (12) Mainshaft Ball Bearing (13) 1st Gear Thrust Bearing (14) 1st Gear (15) 1st Inside Ring
(16) 1st Outside Ring (17) 1st Block Ring (18) Needle Bearing (19) Clutch Hub Snap Ring (20) 1st-2nd Synchronizer Assembly (21) 2nd Block Ring (22) 2nd Outside Ring (23) 2nd Inside Ring (24) 2nd Gear (25) Needle Bearing (26) Mainshaft (27) Bearing Snap Ring (28) Front Roller Bearing (29) Center Roller Bearing (30) Counter Gear Shaft
MANUAL TRANSMISSION
7B1-39
Disassembly
1. Use a pair of snap ring pliers to remove the top gear shaft snap ring(1). 2. Remove top gear shaft(2) with ball bearing(3). 3. Use a bench press and the bearing remover 5-88400015-0 to remove the ball bearing(3).
6. Use a bench press and the bearing remover 5-88400015-0 to remove the 3rd-4th synchronizer assembly (7) as a set. Disassemble the synchronizer assembly.
226RW217
226RW216
4. Remove needle bearing (4) and top block ring (5), mainshaft snap ring. 5. Use a pair of snap ring pliers to remove the mainshaft snap ring (6).
Legend (1) Springs (2) Sleeve (3) Clutch Hub (4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle bearing (10). 8. Use a bench press and the bearing remover 5-88400015-0 to remove the 1st gear(14) together with the mainshaft ball bearing(12), 1st gear thrust bearing (13), and needle bearing collar (11).
226RS008
226RW218
7B1-40
MANUAL TRANSMISSION 13. Remove needle bearing (25) from mainshaft (26). 14. Remove bearing snap ring (27). 15. Remove the front roller bearing (28) by performing the following steps. Remove the ring, outer race and bearing assembly by using a bench press and remover 5-8840-0015-0. Remove the inner race by using a bench press and remover 5-8840-0015-0.
9.Disassemble 1st inside ring (15), 1st outside ring (16), and 1st block ring (17). 10.Remove needle bearing (18). 11.Use a pair of snap ring pliers to remove the clutch hub snap ring (19).
226RS031
12.Use bench press and the bearing remover 5-88400015-0 to remove the 2nd gear (24) together with 1st-2nd synchronizer assembly (20), 2nd block ring (21), 2nd outside ring (22), and inside ring (23). Disassemble the synchronizer assembly.
226RW219
16. Remove center roller bearing (29) from counter gear shaft (30).
226RW220
MANUAL TRANSMISSION
7B1-41

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Block Ring and Dog Teeth Clearance

Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
226RS035
If the measured value exceeds the specified limit, the block ring must be replaced.
Block Ring and Dog Teeth Clearance Standard Limit 1.5 mm (0.059 in) 0.8 mm (0.032 in)
7B1-42
MANUAL TRANSMISSION
1st-2nd Synchronizer (3-CONE)

Block and Insert Clearance Standard 3.46 - 3.76 mm 3rd-4th (0.136 - 0.148 in) 3.86 4.16 mm 1st-2nd (0.152 - 0.164 in) 3.59 - 3.91 mm Rev.5th (0.141 - 0.154 in)
Limit 4.0 mm (0.158 in) 4.9 mm (0.193 in) 4.1 mm (0.161 in)
Clutch Hub and Insert Clearance

Use a thickness gauge to measure the clearance between the clutch hub and the insert.
226RS036
If the measured value exceeds the specified limit, the 1st-2nd synchronizer assembly must be replaced.
Block Ring and Insert Clearance

Use a vernier caliper or thickness gauge to measure the clearance between the block ring and the insert.
226RS038
If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance Standard 1st-2nd 0.01 0.21 mm 3rd-4th (0.004 - 0.0083 in) 0.09 0.31 mm Rev-5th (0.0035 - 0.0122 in) Limit 0.3 mm (0.012 in) 0.4 mm (0.016 in)
226RS037
If the measured value exceeds the specified limit, the block ring and the insert must be replaced.
MANUAL TRANSMISSION
7B1-43
Mainshaft Run-out
Install the mainshaft to V-blocks. Use a dial indicator to measure the mainshaft central portion run-out.
Gear Inside Diameter Standard 1st 45.000 - 45.013 mm (1.771 - 1.772 in) 3rd 52.000 - 52.013 mm 2nd (2.047 - 2.048 in) 48.000 - 48.013 mm Rev. (1.889 - 1.890 in) 32.000 - 32.013 mm 5th (1.259 - 1.260 in)
Limit 45.100 mm (1.776 in) 52.100 mm (2.051 in) 48.100 mm (1.894 in) 32.100 mm (1.246 in)
Reverse Idler Gear and Idler Gear Shaft Clearance

Use a micrometer to measure the idler gear shaft diameter. Use an inside dial indicator to measure the idler gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced. Mainshaft Run-out Limit: 0.05 mm (0.0020 in)
Gear Inside Diameter

Use an inside dial indicator to measure the gear inside diameter.
226RS041
Calculate the idler gear and idler gear shaft clearance. Idler gear inside diameter-idler gear shaft diameter = idle gear and idler gear shaft clearance. If the measured value exceeds the specified limit, the idle gear and/or the idler gear shaft must be replaced Idler Gear and Idler Gear Shaft Clearance Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in) Limit: 0.150 mm (0.0059 in)
226RS040
If the measured value is less than the specified limit, the gear must be replace.
7B1-44
MANUAL TRANSMISSION
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be measured.
226RS043
Reassembly
226RS042
Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. If the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch Hub Spline Play Standard 1st-2nd 0 - 0.1 mm 3rd-4th (0 - 0.004 in) 0 - 0.2 mm Rev. 5th (0 - 0.008 in) Limit 0.2 mm (0.008 in) 0.3 mm (0.012 in)
1. Install center roller bearing (29) to counter gear shaft (30). Apply engine oil to the bearing inner and outer circumferences. Install the roller bearing in the proper direction. NOTE: Check that outer race moves only in the direction of arrow.
Ball Bearing Play

Use a dial indicator to measure the ball bearing play. Ball Bearing Play Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the following steps. Use bearing installer 5-8840-2194-0 to install the front roller bearing inner race to the counter gear shaft (30). Install the outer race and roller assembly. The snap ring groove must be facing the transmission front side.
MANUAL TRANSMISSION Use bearing installer 5-8840-2194-0 to install the ring.
7B1-45
5. Assemble 2nd inside ring (23), 2nd outside ring (22), and 2nd block ring (21) on 2nd gear (24). Apply engine oil to the synchronizer ring friction surfaces.
RTW47BSH000501
Legend (1) Ring (2) Outer Race and Roller Assembly (3) Inner Race 3. Install bearing snap ring (27) to counter gear shaft (30). 4. Apply engine oil to the needle bearing (25) and the 2nd gear (24) thrust surfaces. Install the needle bearing (25) and the 2nd gear (24) to the mainshaft (26). The 2nd gear (24) dog teeth must be facing the transmission rear side.
226RS047
Legend (1) Block Ring (2) Outside Ring (3) Inside Ring (4) 2nd Gear (5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by performing the following steps: 1. Check that the inserts (3) fit snugly into the clutch hub (5) insert grooves. 2. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration. 3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
226RS046
7B1-46
MANUAL TRANSMISSION
266RS049
226RS050
7. Install the synchronizer assembly (20) to the mainshaft (26). The clutch hub face with the heavy boss must be facing the 2nd gear side.
There are three snap ring sizes available. The snap rings are color coded to indicate their thickness as shown in the figure.
226RS021 226RS048
Clutch Hub and Snap Ring Clearance Standard: 0 - 0.1 mm (0 - 0.004 in)
8. Install clutch hub snap ring(19) by performing the following steps: Select the snap ring which will provide the minimum clearance between the 1st-2nd clutch hub and the snap ring.
Snap Ring Availability Thickness 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in)
Color Coding White Yellow Blue
Use a pair of snap ring pliers to install the snap ring (19) to the mainshaft (26). The snap ring must be fully inserted into the mainshaft snap ring groove.
MANUAL TRANSMISSION
7B1-47
10. Install the 1st gear thrust bearing and the race(13) to the main shaft. The thrust bearing side must be facing the transmission front side.
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st outside ring (16), 1st inside ring (15), and 1st gear (14). Apply engine oil to the needle bearing, 1st gear thrust surfaces and synchronizer ring friction surfaces. The 1st gear dog teeth must be facing the transmission front side.
226RS054
11. Apply engine oil to the mainshaft ball bearing (12) and the mainshaft (26). Install the ball bearing (12) and needle bearing collar (11) to the mainshaft (26). The ball bearing snap ring groove must be facing the transmission rear side. Use a bench press and installer 9-8522-1165-0 to slowly force the collar into place.
226RS053
Legend (1) 1st Gear (2) Needle Bearing (3) Inside Ring (4) Outside Ring (5) Block Ring
226RS055
7B1-48
MANUAL TRANSMISSION
12. Apply engine oil to the needle bearing (10) and the 3rd gear (9) thrust surfaces. Install the needle bearing (10) and the 3rd gear (9) to the mainshaft. The 3rd gear dog teeth must be facing the transmission front side.
226RS049
15. Select and install mainshaft snap ring(6) in the following way: Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.
226RS056
13. Install 3rd block ring (8). 14. Check and install 3rd-4th synchronizer assembly (7) by the following steps: 1. Check that the inserts (3) fit snugly into the clutch hub insert grooves. 2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration. 3. Check that the clutch hub (5) and the sleeve (6) slide smoothly. 4. Install the synchronizer assembly to the mainshaft. The clutch hub face with the heavy boss must be facing the 3rd gear side.
226RS058
226RW221
MANUAL TRANSMISSION
7B1-49
16. Install top block ring (5). Apply grease to the needle bearing (4) inner and outer circumferences and install needle bearing (4) in the top gear shaft (2). 17. Use a bench press to install the top gear shaft ball bearing (3) to the top gear shaft (2).
226RS021
Snap Ring Availability Thickness 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in) Color Coding White Yellow Blue
226RS059
The snap ring groove of the ball bearing (3) must be facing the transmission front side. 18. Use a pair of snap ring pliers to install the top gear shaft snap ring (1) to the top gear shaft (2).
Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the mainshaft snap ring groove.
7B1-50
MANUAL TRANSMISSION
Main Data and Specifications

General Specifications
MUA 5G Transmission type Control method Gear ratio: Transmission 1st 2nd 3rd 4th 5th Rev. Transmission oil capacity Type of lubricant MUA 5S Fully synchronized forward and reverse gears Remote control with the gear shift lever on the floor. 4.008 2.301 1.427 1.000 0.828 3.651 2.95 lit. (3.12 US qt) Engine oil: Refer to the chart in "SECTION 0" 4.357 2.502 1.501 1.000 0.809 3.970
MANUAL TRANSMISSION
7B1-51
Torque Specifications
RTW47BLF001201
About arrow mark, refer to Transmission (MUA) Installation in this section.
7B1-52
MANUAL TRANSMISSION
Torque Specifications (Cont'd)
RTW47BLF000901
MANUAL TRANSMISSION
7B1-53
RTW47BLF000601
7B1-54
MANUAL TRANSMISSION
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Checkpoint Trouble Cause Countermeasure
Gear oil
NG
Insufficient or improper gear oil
Replenish or replace the gear oil
OK
Flywheel pilot bearing
NG
Worn flywheel pilot bearing
Replace the flywheel pilot
OK Bearings (Mainshaft, countershaft, and transfer shaft) OK Gears (Mainshaft, countershaft, reverse idler gear and transfer gears) OK Mainshaft splines Synchronizer clutch hub splines OK NG NG Replace the main shaft and the synchronizer clutch hub
NG
Worn or broken bearing(s)
Replace the bearing(s)
NG
Worn or scuffed gear tooth contact surfaces
Replace the gear(s)
Worn splines
Transmission
Transmission misalignment
Realign the transmission
MANUAL TRANSMISSION
7B1-55
2) NOISY OPERATION
Gear oil (Metallic rattling)
NG
Insufficient or improper engine oil
OK Bearings (Hissing, thumping or bumping) NG
OK
Gears (Growling, humming, or grinding)
NG
Worn, chipped, or cracked gear(s)
Replace the gear(s)
OK Free running gears seizing on the thrust face or the inner face
Gears (Squealing at high speeds)
NG
Replace the gear(s)
OK
Gears (Gear whining)
NG
Lack of backlash between meshing gears
Replace the gear(s)
7B1-56
MANUAL TRANSMISSION
2. HARD SHIFTING
Gear oil
NG
Replenish or replace the engine oil
OK NG Improper clutch pedal free play Readjust the clutch pedal free play
Clutch pedal free play
OK
Change lever operation
NG
Hard operating change lever caused insufficient grease
Repair or regrease the change lever assembly
OK
Change lever play
NG
Worn change lever sliding portions
Repair or replace the applicable parts and regrease
OK
Shift block sleeve movement
NG
Sleeve movement failure
Repair or replace the sleeve
OK
Shift rod and quadrant box sliding faces, and other parts
NG
Worn shift rod and/or sliding faces
Replace the shidt rod and/or the quadrant box
Continued on the next page
MANUAL TRANSMISSION Checkpoint Continued from the previous OK Shift arm and synchronizer sleeve OK NG Worn shift arm and/or synchronizer sleeve groove Trouble Cause Countermeasure
7B1-57
Replace the worn parts
Mainshaft and countershaft thrust play
NG
Worn thrust washer, collar, and/or gear thrust faces
OK
Synchronizer assembly
NG
Worn synchronizer parts
7B1-58
MANUAL TRANSMISSION
3. WALKING OR JUMPING OUT OF GEAR

Change lever play
NG
Insufficient stroke caused by sliding position wear and excessive play
OK NG
Detent ball
Worn detent ball
Replace the detent ball
OK
Detent spring
NG
Detent spring weak or broken
Repair or replace the detent spring
OK
Shift rod and quadrant box sliding faces
NG
Replace the shift rod and/or the quadrant box
OK
Shift arm and synchronizer sleeve
NG
Worn shift arm and/or synchronizer sleeve groove
OK
NG
MANUAL TRANSMISSION Checkpoint Continued from the previous page OK Bearings (Mainshaft, countershaft, and individual gears) OK Mainshaft splines Synchronizer clutch hub splines OK NG Trouble Cause Countermeasure
7B1-59
Worn or broken bearings(s)
NG
Worn splines
Replace the main shaft and the synchronizer clutch hub
NG
Weak or broken spring
Replace the spring
7B1-60
MANUAL TRANSMISSION
4. OIL LEAKAGE
Oil level
NG
Oil level too high
Drain the oil to the correct level
OK NG
Gear oil
Improper gear oil
Replace the gear oil
OK
Drain plug and/or filler plug
NG
Loose plug(s)
Tighten the plug(s) and replenish the oil
OK
Gaskets
NG
Defective or improperly installed gasket(s)
Replace the gasket(s)
OK
Air breather
NG
Air breather not installed Air breather clogged
Install the air breather Replace the air breather
OK
Front cover oil seal
NG
Worn or scratched oil seal
Replace the oil seal
OK
Rear cover oil seal
NG
MANUAL TRANSMISSION
7B1-61
Special Tools (4 2)
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME
5-8840-2155-0 Bearing remover
5-8840-2159-0 Mainshaft end bearing installer
5-8840-2027-0 Puller
5-8840-0015-0 Bearing remover/installer
5-8840-2160-0 Holding fixture
5-8840-2797-0 Rear case oil seal installer
5-8840-0003-0 Holding fixture base
5-8840-0026-0 Front cover oil seal installer
5-8840-2156-0 Wrench
9-8522-1165-0 Mainshaft collar remover
5-8840-0047-0 Tork bit wrench (T45)
5-8840-0007-0 Driver handle
7B1-62
MANUAL TRANSMISSION CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
MANUAL TRANSMISSION
7B1-63
General Description
MUA Transmission (4 4)
A07R300003
The MUA is a constant mesh transmission, synchronized in all speeds. The transmission is designed for a great reduction of the shift effort and the quietest possible operation.
Principle parts of the transmission are the integral clutch housing, the intermediate plate, the rear case, and the gears. The transmission control box is built into the transmission.
7B1-64
MANUAL TRANSMISSION
Transmission (4 4)
Disassembled View
RTW47BLF001001
Legend (1) Gear Control Lever Knob (2) Rear Floor Console (bucket) (3) Front Floor Console (4) Grommet Assembly (5) Gear Control Lever (6) Rear Propeller Shaft (7) Front Propeller Shaft (8) Exhaust Pipe Nut (Diesel engine) (9) Exhaust Pipe Assembly (6VE1)
(10) Transmission-Transfer Fixing Bolt (11) Transfer Assembly (12) Fuel Pipe Bracket (13) Slave Cylinder (14) Rear Mount Nut (15) Transmission Crossmember (16) Starter (Diesel engine only) (17) Transmission Retaining Nut and Bolt (18) Transmission Assembly
MANUAL TRANSMISSION
7B1-65
Removal
1. Disconnect battery ground cable. 2. Remove gear control lever knob (1). 3. Remove rear floor console (2). (Bucket seat) Refer to the section Floor Console. 4. Remove front floor console (3). Refer to the section Floor Console.
5. Remove grommet assembly (4).
745R300006
Legend (1) Knob (2) Rear Floor Console (3) Front Floor Console
RTW47BMH000101
7B1-66
MANUAL TRANSMISSION 11. Remove the exhaust pipe (9). (6VE1 only)
6. Remove gear control lever (5). 7. Raise and support vehicle with suitable stands. 8. Remove rear propeller shaft (6). NOTE: Apply alignment marks on the flange at the differential side. 9. Remove front propeller shaft (7). NOTE: Apply alignment marks on the flange at both front and rear sides.
RTW37ASH000101
12. Disconnect harness connectors and clips on the transfer. Actuator connector Car Speed Sensor
401RS023
10. Loosen the front exhaust pipe fixing nuts (8) at the engine side but not remove them. (Diesel engine only)
810R300069
150R300004
Legend (1) Neutral Switch Connector: Transmission (2) Back up Switch Connector (3) Speed Sensor Connector (4) Actuator Connector (5) 2W - 4W Switch Connector (6) Neutral Switch Connector: Transfer
MANUAL TRANSMISSION 13. Remove transmission-transfer fixing bolts (10), and remove the transfer assembly (11) from the transmission. 14. Disconnect harness connectors and clips on the transmission. Neutral switch; Transmission Back up Switch 2W-4W Switch Neutral Switch; Transfer 15. Remove the fuel pipe brackets (12) with pipes from the transmission (18). 16. Remove slave cylinder (13) and put aside it.
7B1-67
Diesel engine
220LV019
17. Support transmission with a transmission jack.
220R300012

6VE1, C24NE
220RS0001
18. Remove engine rear mount nuts (14) from transmission crossmember (15).
Scan-2
7B1-68
MANUAL TRANSMISSION 22. Remove starter (16). (Diesel engine only)
19. Remove engine rear mount bolts fixing transmission.
220R300009
060L100070
20. Remove the middle part of transmission crossmember (15) by removing four fixing bolts and nuts.
23. Use the clutch release bearing remover 5-88402291-0 (J-39207) to disconnect the clutch release bearing from the clutch pressure plate. (6VE1 only)
501R30007
220RW109
21. Take out the rear support rubber.
Release bearing disconnection 1. Pull the shift fork toward the transmission to press the clutch release bearing against the clutch. 2. Insert the clutch release bearing remover between the wedge collar and the release bearing. 3. Turn the remover to separate the release bearing.
MANUAL TRANSMISSION NOTE: Be sure not to insert the remover between the wedge collar and the clutch.
7B1-69
220RW019
Legend (1) Pressure Plate Assembly (2) Release Bearing (3) Wedge Collar
24. Remove transmission retaining nuts and bolts(17). Remove transmission assembly (18) from the vehicle.
Installation
220RW063
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline. 2. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same. 3. Align the top gear shaft with the clutch driven plate spline.
220RW064
7B1-70
MANUAL TRANSMISSION
4. Install the transmission assembly (18) to the engine. Tighten the transmission nuts and bolts as shown in the figure. Diesel engine
RTW37BLF000901
MANUAL TRANSMISSION 6VE1
7B1-71
RTW37BLF0001
7B1-72
MANUAL TRANSMISSION
RTW37BLF000201
5. Apply a force of about 113N (26 Ib) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing. (6VE1 only) NOTE: A clicking sound is heard when the release bearing and the tip of the diaphragm spring engage each other. Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine while applying a force of about 25 N (5.5 lb). If the shift fork will not move, then they are securely engaged.
220RS006
MANUAL TRANSMISSION 6. Install starter(16).(Diesel engine) NOTE: Tighten the lower bolt temporarily. After installing the fuel pipe assembly, tighten the bolt to the specified torque. Torque: 76 N+m (7.7 kg+m/56 lb+ft) 7. Install the rear support rubber on the transmission and tighten the bolts to the specified torque. Torque: 50 N+m (5.1 kg+m/37 lb+ft) 8. Install the middle part of transmission crossmember (15) and bolts. Tighten the nuts to the specified torque. Torque: 67 N+m (6.8 kg+m/49 lb+ft) 9. Install engine rear mount nuts (14). Torque: 52 N+m (5.3 kg+m/38 lb+ft) Remove the transmission jack from transmission side. 10. Apply grease to top hole portion of the shift fork. Install slave cylinder (13) and tighten the bolts to the specified torque. Torque: 76 N+m (7.7 kg+m/56 lb+ft) 11. Install the fuel pipe brackets on the transmission. Install the fuel pipe assembly to the fuel pipe brackets Torque: Bolt & Nut Nut 76 N+m (7.7 kg+m/56 lb+ft) 37 N+m (3.8 kg+m/28 lb+ft)
6VE1, C24NE
7B1-73
Scan-2
12. Connect transmission harness connectors and clips. Connector: transfer neutral switch, 2W - 4W switch, backup switch, transmission neutral switch.
Diesel engine
810R300069
220R300012
Legend (1) Neutral Switch Connector: Transmission (2) Backup Switch Connector (3) Speed Sensor Connector (4) Actuator Connector (5) 2W - 4W Switch connector (6) Neutral Switch Connector: Transfer
13. Apply grease (BESCO L2 or equivalent) on the splined portion of the output shaft. 14. Connect the transfer to the transmission.
7B1-74
MANUAL TRANSMISSION 18. Install the exhaust pipe (9). (6VE1) Torque: 67 N+m (6.8 kg+m/49 lb+ft)
15. Install the transmission-transfer bolts and nut and tighten them to the specified torque. Torque: 41 N+m (4.2 kg+m/30 lb+ft)
RTW37ASH000101 261R300005
19. Install front propeller shaft (7). Refer to the section Front Propeller Shaft. 20. Install rear propeller shaft (6). Torque: 63 N+m (6.4 kg+m/46 lb+ft) 21. Install the center bearing on crossmember. Torque: 69 N+m (7.0 kg+m/51 lb+ft) 22. Install gear control lever (5). Torque: 19 N+m (1.9 kg+m/14 lb+ft)
MANUAL TRANSMISSION 21. Install grommet assembly (4). Torque: Screw Nut 1.4 N+m (0.14 kg+m/12 lb+in) 7 N+m (0.7 kg+m/61 lb+in)
7B1-75
RTW47BMH000101
Legend (1) Grommet Assembly (2) Floor Panel (3) Front 24. Install front floor console (3) and rear floor console (2). 25. Install gear control lever knob (1). To the female thread portion, adhesive (TB1344 or LOCTITE 222 or equiv.) of 3 - 4 drops to be applied and transmission knob tightened. Torque: 9 N+m (0.9 kg+m/78 lb+in) After tightening to specified torque, knob rewrenched until direction of shift pattern due positioned. 26. Connect battery ground cable.
7B1-76
MANUAL TRANSMISSION
Transmission Case
Major Component
RTW47BLF000101
Legend (1) Gear Control Box Assembly and Gasket (2) Rear Case Assembly (3) Intermediate Plate with Gear Assembly (4) Transmission Case (5) Release Bearing (with Spring): 4JH1-TC (6) Shift Fork: 4JH1-TC (7) Counter Front Bearing Snap Ring
(8) Front Cover (with Oil Seal) (9) Top Gear Bearing Snap Ring (10) Release Bearing : C24NE (11) Shift Fork : C24NE (12) Fulcrum Bridge : 6VE1 (13) Release Bearing : 6VE1 (14) Shift Fork : 6VE1
MANUAL TRANSMISSION
7B1-77
Disassembly
1. Clean the exterior of the unit with solvent. 2. Remove the drain plug from the transmission case and drain the lubricant. 3. Remove the clutch release bearing with spring (5) from the transmission case. 4. Remove the shift fork, and boot. (Diesel engine, C24NE) 5. Remove the shift fork snap pin. (6VE1) 6. Remove the shift fork pin and shift fork from the fulcrum bridge. (6VE1)
7. Remove the fulcrum bridge from the transmission case. (6VE1)
RTW37ASH0002
8. Remove the front cover (8) and gasket from the transmission case. 9. Remove snap ring (7) fixing counter front bearing. 10. Use a pair of snap ring pliers to remove the snap ring (9) fixing top gear bearing.
RTW47BSH000601
Legend (1) Shift fork pin (2) Shift fork (3) Release bearing
226RS001
11. Remove gear control box assembly (1). 12. Remove the rear case assembly (2) from the transmission case (4) and intermediate plate (3). 13. Remove intermediate plate with gear assembly (3) from transmission case (4).
7B1-78
MANUAL TRANSMISSION
Rear Oil Seal Replacement
220R300026 220R300025
Legend (1) Installer 5-8840-2797-0 (2) Grip 5-8840-0007-0

1. Remove the oil seal from the rear case and discard the used oil seal. 2. Apply engine oil to new oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip. 4. Use the oil seal installer 5-8840-2797-0 and grip 58840-0007-0 to install the oil seal to the rear case.
Notes When Tightening the Bolt: After cleaning the bolt hole, dry it thoroughly with air. After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent on them before tightening it. 4. Install a new gasket and gear control box assembly (1). Install the harness clips and brackets and then tighten four new gear control box bolts to the specified torque. Torque: 20 N+m (2.0 kg+m/14 lb+ft)
Reassembly
1. Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transmission case (4), intermediate plate (3) and rear case (2) fitting surfaces. 2. Install the intermediate plate with gear assembly (3) to the transmission case (4). Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face. Avoid subjecting the mainshaft to sudden shock or stress. 3. Install the rear case with oil seal (2) on the intermediate plate with gear (3) by performing the following steps. Cover the shaft splines with adhesive tape. This will prevent damage to the oil seal lip. Tighten the transmission rear case bolts and nuts to the specified torque. Torque: 37 N+m (3.8 kg+m/27 lb+ft)
261R300004
MANUAL TRANSMISSION 5. Install top gear bearing snap ring (9) and counter front bearing snap ring (7). Use a pair of snap ring pliers to install the snap rings to the mainshaft and countershaft. The snap rings must be fully inserted into the bearing snap ring groove. 6. Front cover with oil seal (8). Front Cover Oil Seal Replacement Remove the oil seal from the front cover. Apply engine oil to a new oil seal outer circumference. Apply recommended grease to the oil seal lip. Use the oil seal installer 5-8840-0026-0 to install the oil seal to the front cover.
7B1-79
8. Apply molybdenum disulfide type grease to the areas as shown in the figure and install shift fork (6). (Diesel engine, C24NE)
F07L100026
9. Install the fulcrum bridge to the transmission case. (6VE1) Torque: 38 N+m (3.9 kg+m/28 lb+ft)
220R3000020
RTW37ASH0002

10. Apply molybdenum disulfide type grease to the pin hole inner circumferences and thrust surfaces. (6VE1) 11. Attach the shift fork to the fulcrum bridge and insert the pin from below of the fulcrum bridge. (6VE1)
7B1-80
MANUAL TRANSMISSION
12. Install the washer and snap pin. (6VE1)
RTW47BMH000201
13. Pack the inside recess (A) and coat the back (B) of the release bearing with molybdenum disulfide type grease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover, joining it to the shift fork.
MANUAL TRANSMISSION
7B1-81
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and Interlock Pin
Disassembled View
RTW47BLF000501
Legend (1) Detent Spring Plate and Gasket (2) Detent Spring (3) Detent Ball (4) Spring (5) Rev-5th Shift Rod (6) Rev-5th Shift Arm and Reverse Inhibitor
(7) 1st-2nd Shift Rod (8) 3rd-4th Shift Rod (9) 3rd-4th Shift Arm (10) 1st-2nd Shift Arm (11) Interlock Pin (12) Intermediate Plate and Gear Assembly
7B1-82
MANUAL TRANSMISSION
Disassembly
1. Remove detent spring plate and gasket (1), detent spring (2) and detent ball (3). Use a magnetic hand to remove the detent balls from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when pulling out the shift rod rearward. Interlock pins are located between the shifter rods in the intermediate plate.
220RS011
2. Remove spring (4). 3. Remove rev-5th shift rod (5), and rev-5th shift arm and reverse inhibitor (6). Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8), 3rd-4th shift arm (9), and 1st-2nd shift arm (10). Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift rods carefully. 4. Remove interlock pin (11) from intermediate plate and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift arm spring pins from the shift arms and the shift rods.
MANUAL TRANSMISSION
7B1-83

Make the necessary adjustments, and part replacements if excessive wear or damage is discovered during inspection.
Shift Arm Thickness

Use a micrometer to measure the shift arm thickness. If the measured value is less than the specified limit, the shift arm must be replaced.
Shift Arm Thickness Standard 9.60 - 9.85 mm 1st-2nd (0.378 - 0.388 in) 3rd-4th 9.60 - 9.80 mm Rev.5th (0.378 - 0.386 in)
Limit 9.0 mm (0.354 in)
220RS012
Detent Spring Tension

Use a spring tester to measure the detent spring tension. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring Tension Compressed height 20 mm (0.787 in)
Standard 87.2 - 97.1 N (19.6 - 21.8 lb)
230RS006
Detent Spring Free Length

Use a vernier caliper to measure the detent spring free length. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring Free Length Standard 26.8 mm (1.06 in)
SOUTH AFRICA 5th-Rev Only Detent Spring Free Length Standard Outer 27.6 mm (1.09 in) Inner 26.6 mm (1.05 in)
Limit 26.2 mm (1.03 in)
220RS013
Limit 27.0 mm (1.06 in) 26.0 mm (1.02 in)
SOUTH AFRICA 5th-RV Only Detent Spring Free Length Compressed Outer Inner 20 mm (0.787 in) 20 mm (0.787 in)
Standard 93.5 103.3 N (21.0 23.3 lb) 26.4 36.3 N (5.9 8.2 lb)
7B1-84
MANUAL TRANSMISSION 4. Install spring (4). 5. Put detent balls (3) in the intermediate plate holes. Apply oil to the detent balls. 6. Install detent springs (2) and detent spring plate and gasket (1). Install a new gasket and the detent spring plate. Tighten the detent spring plate bolts to the specified torque. Torque: 25 N+m (2.5 kg+m/18 lb+ft)
Reassembly
1. Install rev-5th shift arm and reverse inhibitor (6) and rev-5th shift rod (5). Apply oil to the reverse inhibitor inner surface. Install the shift rod in the intermediate plate (12). Hold a round bar against the shift rod end lower face to protect it against damage. Install a new spring pin. Never reinstall the used spring pin. Install the interlock pin (11) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate (12). 2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9) to intermediate plate and gear assembly (12). 3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7). Install the interlock pin (11) in the intermediate plate and gear assembly (12). Install the 3rd-4th shift rod (8) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate. Install the interlock pin (11) and then 1st-2nd shift rod (7) in the intermediate plate (12). Do not allow the interlock pin to fall from the intermediate plate. Hold a round bar against the shift rod end lower face to protect it against damage. Install a new spring pin. Never reinstall the used spring pin.
220RS030
Legend (1) Warped
230RS007
MANUAL TRANSMISSION
7B1-85
Reverse Gear and 5th Gear

Disassembled View
226R300024
Legend (1) Collar Snap Ring (2) Oil Seal Collar (3) Ball Bearing (4) Retainer (5) Thrust Plate (6) Thrust Washer and Lock Ball (7) Reverse Idler Gear Snap Ring (8) Reverse Idler Gear Assembly (9) Idle Shaft Pin (10) Thrust Washer (11) Reverse Idler Gear (12) Reverse Idler Shaft (13) Bearing Snap Ring (14) Ball Bearing
(15) Counter 5th Gear (16) Counter Reverse Gear (17) 5th Gear (18) 5th Block Ring (19) Needle Bearing (20) Mainshaft Nut (21) Rev-5th Synchronizer Assembly (22) Reverse Block Ring (23) Reverse Gear (24) Needle Baring (25) Bearing Plate and Screw (26) Bearing Snap Ring (27) Intermediate Plate
7B1-86
MANUAL TRANSMISSION 6. Remove the reverse idler gear assembly (8) from the intermediate plate (27).
Disassembly
1. Use a pair of snap ring pliers to remove the collar snap ring (1). 2. Set the retaining ring remover 5-8840-2158-0 and puller 5-8840-2027-0 to the retainer (4) and the mainshaft end.
226RS005
262RW079
3. Remove the retainer (4) together with the bearing (3) and the oil seal collar (2). The universal puller may be used in place of the retaining ring remover. 4. Remove thrust plate (5) and thrust washer and lock ball (6). 5. Use a pair of snap ring pliers to remove reverse idler gear snap ring (7).
7. Remove idle shaft pin (9), thrust washer (10), reverse idler gear (11), and reverse idler shaft (12). 8. Use a pair of snap ring pliers to remove the snap ring (13). 9. Attach a universal puller to the counter gear shaft. Use a universal puller to remove the ball bearing (14) and the counter 5th gear (15).
226RS006
10. Remove counter reverse gear (16).
226RS004
MANUAL TRANSMISSION 11. Remove 5th gear (17), 5th block ring (18), and needle bearing (2 piece type) (19).
7B1-87
226RW210
226RS007
Use the mainshaft nut wrench 5-8840-2156-0 to remove the mainshaft nut (20).
12. Remove the mainshaft nut (20) according to following steps. Attach the holding fixture 5-8840-2160-0 and base 5-8840-0003-0 to the mainshaft and the counter gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd gear. Engage the 1st-2nd synchronizer with the 1st gear.
7B1-88
MANUAL TRANSMISSION
13. Use screw drivers between the reverse gear (23) and bearing plate (25) to remove the Rev-5th synchronizer assembly (21) together with reverse block ring (22) and reverse gear (23).
226RS011
17. Hold the snap ring open with the pliers. Push the intermediate plate (27) toward the rear of the transmission to remove it.
226RS010
14. Remove needle bearing (24). 15. Use the torx bit wrench (T45) 5-8840-0047-0 to remove the bearing plate and screw(25) from the intermediate plate.
The bearing snap ring will come free.

Refer to Top Gear Shaft, Main Gear Shaft, and Counter Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly. Set the holding fixture 5-8840-2160-0 to the mainshaft and the counter gear and then install it on the base 5-8840-0003-0. Install the intermediate plate (27) on the gear assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft bearing snap ring (2) (26).
226RW212
MANUAL TRANSMISSION 2. Install bearing snap ring (26). 3. Apply recommended thread locking agents (LOCTITE 242) or its equivalent to each of the bearing plate screw threads. Install bearing plate and screw (25). Tighten the screws to the specified torque by using torx bit wrench 5-8840-0047-0. Torque: 15 N+m (1.5 kg+m/11 lb+ft)
7B1-89
5. Assemble rev-5th synchronizer assembly (21) by performing the following steps. 1. Turn the clutch hub face (1) toward the sleeve groove (2) (rear side) on the outer circumference. 2. Check that the inserts (3) fit snugly into the clutch hub (5) ring insert grooves. 3. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration. 4. Check that the clutch hub (5) and the sleeve (6) slide smoothly. 5. Install the synchronizer assembly (21) to the mainshaft. The clutch hub face with the heavy boss must be facing the reverse gear side.
220RW137
4. Install needle bearing (24), reverse gear (23), and reverse block ring (22).
226RS013
226RS049
7B1-90
MANUAL TRANSMISSION 8. Use a punch to stake the mainshaft nut (20).
6. Mesh the 1st-2nd and 3rd-4th synchronizers with both the 1st and 3rd gears (double engagement).
226RW153 226RS015
This will prevent the mainshaft from turning. 7. Install the new mainshaft hub nut. Use the mainshaft nut wrench 5-8840-2156-0 to tighten the mainshaft nut (20) to the specified torque. Torque: 137 N+m (14 kg+m/101 lb+ft)
9. Install needle bearing (19), 5th block ring (18), and 5th gear (17). 10. Apply engine oil to the counter reverse gear (16) and the reverse gear (23). Install the counter reverse gear (16) to the counter shaft. The reverse gear projection must be facing the intermediate plate.
226RW214 226RW151
MANUAL TRANSMISSION 11. Install the counter 5th gear (15) to the counter shaft.
7B1-91
There are six snap ring sizes available. The snap rings are color&dash;coded to indicate their thickness.
226RS019
12. Install ball bearing (14) and bearing snap ring (13) by performing the following steps: Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.
226RS021
Ball Bearing and Snap Ring Clearance Standard: 0 - 0.15 mm (0 - 0.0059 in) Snap Ring Availability Thickness Color Coding 1.1 mm (0.043 in) White 1.2 mm (0.047 in) Yellow 1.3 mm (0.051 in) Blue 1.4 mm (0.055 in) Pink 1.5 mm (0.059 in) Green 1.6 mm (0.063 in) Brown Use a pair of snap ring pliers to install the snap ring(13) to the counter gear shaft. The snap ring must be fully inserted into the counter gear shaft snap ring groove. 13. Assemble reverse idler shaft (12), reverse idler gear (11), thrust washer (10), and idle shaft pin (9) into reverse idler gear assembly (8). The trust washer should be assembled as oil groove faces to gear side.
226RS020
7B1-92
MANUAL TRANSMISSION Use a pair of snap ring pliers to install the snap ring to the reverse idler shaft. The snap ring must be fully inserted into the reverse idler shaft snap ring groove. 15. Install thrust washer and lock ball (6) by performing the following steps: Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer. 5th Gear and Thrust Washer Clearance Standard: 0.10 - 0.25 mm (0.004 - 0.010 in)) Measure clearance "A" as shown in the figure.
14. Select reverse idler gear snap ring (7) which will provide the minimum clearance between the intermediate plate (27) and the snap ring (7).
226RS022
There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness. Intermediate Plate and Snap Ring Clearance Standard: 0 - 0.15 mm (0 - 0.0059 in) Snap Ring Availability Thickness Color Coding 1.2 mm (0.047 in) White 1.3 mm (0.051 in) Yellow 1.4 mm (0.055 in) Blue
226RS023
Select appropriate thrust washer from chart. There are four thrust washer sizes available. Thrust Washer Availability Thickness Color Clearance A mm (in) mm (in) Coding mm (in) 8.05 - 8.1 0.15 - 0.25 7.9 (0.311) White (0.317-0.319) (0.006-0.010) 8.1 - 8.2 0.1 - 0.25 8.0 (0.315) Yellow (0.319-0.323) (0.004-0.010) 8.2 - 8.3 0.1 - 0.25 8.1 (0.319) Green (0.323-0.327) (0.004-0.010) 8.3 - 8.36 0.1 - 0.21 8.2 (0.323) Blue (0.327-0.329) (0.004-0.008) The thrust washers are color coded to indicate their thickness as shown in the figure.
226RS021
MANUAL TRANSMISSION
7B1-93
18. Apply engine oil to the oil seal collar inner circumference. Install the oil seal collar (2) to the mainshaft by using the installer 5-8840-2159-0. 19. Install the oil seal collar snap ring (1).
226RS024
Apply grease to the thrust washer and the lock ball. Install the thrust washer and the lock ball. 16. Install thrust plate (5) and retainer (4). 17. Apply engine oil to the bearing inner and outer circumference. Use the installer 5-8840-2159-0 to install the ball bearing (3) to the mainshaft.
226L100002
7B1-94
MANUAL TRANSMISSION
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
MANUAL TRANSMISSION Legend (1) Top Gear Shaft Snap Ring (2) Top Gear Shaft (3) Ball Bearing (4) Needle Bearing (5) Top Block Ring (6) Mainshaft Snap Ring (7) 3rd-4th Synchronizer Assembly (8) 3rd Block Ring (9) 3rd Gear (10) Needle Bearing (11) Needle Bearing Collar (12) Mainshaft Ball Bearing (13) 1st Gear Thrust Bearing (14) 1st Gear (15) 1st Inside Ring
7B1-95
(16) 1st Outside Ring (17) 1st Block Ring (18) Needle Bearing (19) Clutch Hub Snap Ring (20) 1st-2nd Synchronizer Assembly (21) 2nd Block Ring (22) 2nd Outside Ring (23) 2nd Inside Ring (24) 2nd Gear (25) Needle Bearing (26) Mainshaft (27) Bearing Snap Ring (28) Front Roller Bearing (29) Center Roller Bearing (30) Counter Gear Shaft
7B1-96
MANUAL TRANSMISSION 6. Use a bench press and the bearing remover 5-88400015-0 to remove the 3rd-4th synchronizer assembly (7) as a set. Disassemble the synchronizer assembly.
Disassembly
1. Use a pair of snap ring pliers to remove the top gear shaft snap ring(1). 2. Remove top gear shaft(2) with ball bearing(3). 3. Use a bench press and the bearing remover 5-88400015-0 to remove the ball bearing(3).
226RW217
226RW216
4. Remove needle bearing (4) and top block ring (5), mainshaft snap ring. 5. Use a pair of snap ring pliers to remove the mainshaft snap ring (6).
7. Remove 3rd block ring (8), 3rd gear (9), and needle bearing (10). 8. Use a bench press and the bearing remover 5-88400015-0 to remove the 1st gear(14) together with the mainshaft ball bearing(12), 1st gear thrust bearing (13), and needle bearing collar (11).
226RS008
226RW218
MANUAL TRANSMISSION 9.Disassemble 1st inside ring (15), 1st outside ring (16), and 1st block ring (17). 10.Remove needle bearing (18). 11.Use a pair of snap ring pliers to remove the clutch hub snap ring (19).
7B1-97
13. Remove needle bearing (25) from mainshaft (26). 14. Remove bearing snap ring (27). 15. Remove the front roller bearing (28) by performing the following steps. Remove the ring, outer race and bearing assembly by using a bench press and remover 5-8840-0015-0. Remove the inner race by using a bench press and remover 5-8840-0015-0.
226RS031
12.Use bench press and the bearing remover 5-88400015-0 to remove the 2nd gear (24) together with 1st-2nd synchronizer assembly (20), 2nd block ring (21), 2nd outside ring (22), and inside ring (23). Disassemble the synchronizer assembly.
226RW219
16. Remove center roller bearing (29) from counter gear shaft (30).
226RW220
7B1-98
MANUAL TRANSMISSION

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Block Ring and Dog Teeth Clearance

226RS035
If the measured value exceeds the specified limit, the block ring must be replaced.
MANUAL TRANSMISSION
7B1-99
1st-2nd Synchronizer (3-CONE)

Block and Insert Clearance Standard 3.46 - 3.76 mm 3rd-4th (0.136 - 0.148 in) 3.86 4.16 mm 1st-2nd (0.152 - 0.164 in) 3.59 - 3.91 mm Rev.5th (0.141 - 0.154 in)
Limit 4.0 mm (0.158 in) 4.9 mm (0.193 in) 4.1 mm (0.161 in)
Clutch Hub and Insert Clearance

Use a thickness gauge to measure the clearance between the clutch hub and the insert.
226RS036
If the measured value exceeds the specified limit, the 1st-2nd synchronizer assembly must be replaced.
Block Ring and Insert Clearance

Use a vernier caliper or thickness gauge to measure the clearance between the block ring and the insert.
226RS038
If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance Standard 1st-2nd 0.01 0.21 mm 3rd-4th (0.004 - 0.0083 in) 0.09 0.31 mm Rev-5th (0.0035 - 0.0122 in) Limit 0.3 mm (0.012 in) 0.4 mm (0.016 in)
226RS037
If the measured value exceeds the specified limit, the block ring and the insert must be replaced.
7B1-100
MANUAL TRANSMISSION
Mainshaft Run-out
Install the mainshaft to V-blocks. Use a dial indicator to measure the mainshaft central portion run-out.
Gear Inside Diameter Standard 1st 45.000 - 45.013 mm (1.771 - 1.772 in) 3rd 52.000 - 52.013 mm 2nd (2.047 - 2.048 in) 48.000 - 48.013 mm Rev. (1.889 - 1.890 in) 32.000 - 32.013 mm 5th (1.259 - 1.260 in)
Limit 45.100 mm (1.776 in) 52.100 mm (2.051 in) 48.100 mm (1.894 in) 32.100 mm (1.246 in)
Reverse Idler Gear and Idler Gear Shaft Clearance

Use a micrometer to measure the idler gear shaft diameter. Use an inside dial indicator to measure the idler gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced. Mainshaft Run-out Limit: 0.05 mm (0.0020 in)
Gear Inside Diameter

Use an inside dial indicator to measure the gear inside diameter.
226RS041
Calculate the idler gear and idler gear shaft clearance. Idler gear inside diameter-idler gear shaft diameter = idle gear and idler gear shaft clearance. If the measured value exceeds the specified limit, the idle gear and/or the idler gear shaft must be replaced Idler Gear and Idler Gear Shaft Clearance Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in) Limit: 0.150 mm (0.0059 in)
226RS040
If the measured value is less than the specified limit, the gear must be replace.
MANUAL TRANSMISSION
7B1-101
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be measured.
226RS043
Reassembly
226RS042
Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. If the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch Hub Spline Play Standard 1st-2nd 0 - 0.1 mm 3rd-4th (0 - 0.004 in) 0 - 0.2 mm Rev. 5th (0 - 0.008 in) Limit 0.2 mm (0.008 in) 0.3 mm (0.012 in)
1. Install center roller bearing (29) to counter gear shaft (30). Apply engine oil to the bearing inner and outer circumferences. Install the roller bearing in the proper direction. NOTE: Check that outer race moves only in the direction of arrow.
Ball Bearing Play

Use a dial indicator to measure the ball bearing play. Ball Bearing Play Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the following steps. Use bearing installer 5-8840-2194-0 to install the front roller bearing inner race to the counter gear shaft (30). Install the outer race and roller assembly. The snap ring groove must be facing the transmission front side.
7B1-102
MANUAL TRANSMISSION 5. Assemble 2nd inside ring (23), 2nd outside ring (22), and 2nd block ring (21). Apply engine oil to the synchronizer ring friction surfaces.
Use bearing installer 5-8840-2194-0 to install the ring.
226RS045 Legend (1) Ring (2) Outer Race and Roller Assembly (3) Inner Race 3. Install bearing snap ring (27) to counter gear shaft (30). 4. Apply engine oil to the needle bearing (25) and the 2nd gear (24) thrust surfaces. Install the needle bearing (25) and the 2nd gear (24) to the mainshaft (26). The 2nd gear (24) dog teeth must be facing the transmission rear side.
226RS047
Legend (1) Block Ring (2) Outside Ring (3) Inside Ring (4) 2nd Gear (5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by performing the following steps: 1. Check that the inserts (3) fit snugly into the clutch hub (5) insert grooves. 2. Check that the inserts springs (4) are fitted to the inserts as shown in the illustration. 3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
226RS046
MANUAL TRANSMISSION
7B1-103
266RS049
226RS050
7. Install the synchronizer assembly (20) to the mainshaft (26). The clutch hub face (with the heavy boss) must be facing the 2nd gear side.
226RS021 226RS048
Snap Ring Availability Thickness 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in) Color Coding White Yellow Blue
8. Install clutch hub snap ring(19) by performing the following steps: Select the snap ring which will provide the minimum clearance between the 1st-2nd clutch hub and the snap ring.
Use a pair of snap ring pliers to install the snap ring (19) to the mainshaft (26). The snap ring must be fully inserted into the mainshaft snap ring groove.
7B1-104
MANUAL TRANSMISSION 10. Install the 1st gear thrust bearing and the race(13) to the main shaft. The thrust bearing side must be facing the transmission front side.
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st outside ring (16), 1st inside ring (15), and 1st gear (14). Apply engine oil to the needle bearing, 1st gear thrust surfaces and synchronizer ring friction surfaces. The 1st gear dog teeth must be facing the transmission front side.
226RS054
11. Apply engine oil to the mainshaft ball bearing (12) and the mainshaft (26). Install the ball bearing (12) and needle bearing collar (11) to the mainshaft (26). The ball bearing snap ring groove must be facing the transmission rear side. Use a bench press and installer 9-8522-1165-0 to slowly force the collar into place.
226RS053
Legend (1) 1st Gear (2) Needle Bearing (3) Inside Ring (4) Outside Ring (5) Block Ring
226RS055
MANUAL TRANSMISSION 12. Apply engine oil to the needle bearing (10) and the 3rd gear (9) thrust surfaces. Install the needle bearing (10) and the 3rd gear (9) to the mainshaft. The 3rd gear dog teeth must be facing the transmission front side.
7B1-105
226RS049
15. Select and install mainshaft snap ring(6) in the following way: Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.
226RS056
13. Install 3rd block ring (8). 14. Check and install 3rd-4th synchronizer assembly (7) by the following steps: 1. Check that the inserts (3) fit snugly into the clutch hub insert grooves. 2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration. 3. Check that the clutch hub (5) and the sleeve (6) slide smoothly. 4. Install the synchronizer assembly to the mainshaft. The clutch hub face with the heavy boss must be facing the 3rd gear side.
226RS058
226RW221
7B1-106
MANUAL TRANSMISSION 16. Install top block ring (5). Apply grease to the needle bearing (4) inner and outer circumferences and install needle bearing (4) in the top gear shaft (2). 17. Use a bench press to install the top gear shaft ball bearing (3) to the top gear shaft (2).
226RS021
Snap Ring Availability Thickness 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in)
Color Coding White Yellow Blue
226RS059
The snap ring groove of the ball bearing (3) must be facing the transmission front side. 18. Use a pair of snap ring pliers to install the top gear shaft snap ring (1) to the top gear shaft (2).
Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the mainshaft snap ring groove.
MANUAL TRANSMISSION
7B1-107
Main Data and Specifications

General Specifications
MUA5G MUA5S Fully synchronized forward and reverse gears Remote control with the gear shift lever on the floor. 4.008 4.357 2.301 2.502 1.427 1.501 1.000 1.000 0.828 0.809 3.651 3.970 2.95 lit. (3.12 US qt) Engine oil: Refer to the chart in "SECTION 0"
Transmission type Control method Gear ratio: Transmission
1st 2nd 3rd 4th 5th Rev.
Transmission oil capacity Type of lubricant
7B1-108
MANUAL TRANSMISSION
Torque Specifications
RTW47BLF001101
About arrow mark, refer to Transmission (MUA) Installation in this section.
MANUAL TRANSMISSION
7B1-109
RTW47BLF000801
7B1-110
MANUAL TRANSMISSION
RTW47BLF000601
MANUAL TRANSMISSION
7B1-111
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Gear oil
NG
OK
Flywheel pilot bearing
NG
Worn flywheel pilot bearing
Replace the flywheel pilot
OK Bearings (Mainshaft, countershaft, and transfer shaft) OK Gears (Mainshaft, countershaft, reverse idler gear and transfer gears) OK Mainshaft splines Synchronizer clutch hub splines OK NG NG Replace the main shaft and the synchronizer clutch hub
NG
NG
Worn or scuffed gear tooth contact surfaces
Replace the gear(s)
Worn splines
Transmission
Transmission misalignment
Realign the transmission
7B1-112
MANUAL TRANSMISSION
2) NOISY OPERATION
Gear oil (Metallic rattling)
NG
Insufficient or improper engine oil
OK Bearings (Hissing, thumping or bumping) NG
OK
Gears (Growling, humming, or grinding)
NG
Worn, chipped, or cracked gear(s)
Replace the gear(s)
OK Free running gears seizing on the thrust face or the inner face
Gears (Squealing at high speeds)
NG
Replace the gear(s)
OK
Gears (Gear whining)
NG
Lack of backlash between meshing gears
Replace the gear(s)
MANUAL TRANSMISSION
7B1-113
2. HARD SHIFTING
Gear oil
NG
Replenish or replace the engine oil
OK NG Improper clutch pedal free play Readjust the clutch pedal free play
Clutch pedal free play
OK
Change lever operation
NG
Hard operating change lever caused insufficient grease
Repair or regrease the change lever assembly
OK
Change lever play
NG
Worn change lever sliding portions
Repair or replace the applicable parts and regrease
OK
Shift block sleeve movement
NG
Sleeve movement failure
Repair or replace the sleeve
OK
Shift rod and quadrant box sliding faces, and other parts
NG
Replace the shidt rod and/or the quadrant box
7B1-114
MANUAL TRANSMISSION Checkpoint Trouble Cause Countermeasure
Continued from the previous OK Shift arm and synchronizer sleeve OK NG Worn shift arm and/or synchronizer sleeve groove
NG
OK
NG
Worn synchronizer parts
MANUAL TRANSMISSION
7B1-115
3. WALKING OR JUMPING OUT OF GEAR

Change lever play
NG
Insufficient stroke caused by sliding position wear and excessive play
OK NG
Detent ball
Worn detent ball
Replace the detent ball
OK
Detent spring
NG
Detent spring weak or broken
Repair or replace the detent spring
OK
Shift rod and quadrant box sliding faces
NG
Replace the shift rod and/or the quadrant box
OK
Shift arm and synchronizer sleeve
NG
Worn shift arm and/or synchronizer sleeve groove
OK
NG
7B1-116
MANUAL TRANSMISSION Checkpoint Trouble Cause Countermeasure
Continued from the previous page OK Bearings (Mainshaft, countershaft, and individual gears) OK Mainshaft splines Synchronizer clutch hub splines OK NG
Worn or broken bearings(s)
NG
Worn splines
Replace the main shaft and the synchronizer clutch hub
NG
Weak or broken spring
Replace the spring
MANUAL TRANSMISSION
7B1-117
4. OIL LEAKAGE
Oil level
NG
Oil level too high
Drain the oil to the correct level
OK NG
Gear oil
Improper gear oil
Replace the gear oil
OK
Drain plug and/or filler plug
NG
Loose plug(s)
Tighten the plug(s) and replenish the oil
OK
Gaskets
NG
Defective or improperly installed gasket(s)
Replace the gasket(s)
OK
Air breather
NG
Air breather not installed Air breather clogged
Install the air breather Replace the air breather
OK
Front cover oil seal
NG
OK
Rear cover oil seal
NG
7B1-118
MANUAL TRANSMISSION
Special Tools (4 4)
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME
5-8840-2159-0 Mainshaft end bearing installer
5-8840-2027-0 Puller
5-8840-0015-0 Bearing remover/installer
5-8840-2160-0 Holding fixture
5-8840-2797-0 Rear case oil seal installer
5-8840-0003-0 Holding fixture base
5-8840-0026-0 Front cover oil seal installer
5-8840-2156-0 Wrench
5-8840-0047-0 Tork bit wrench (T45)
5-8840-0007-0 Driver handle
No. TFMUA-WE-0431

07 - Tfmua We 0431

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WORKSHOP MANUAL

SECTION 7B1 MANUAL TRANSMISSION MUA CONTENTS

Troubleshooting............................................................................................................... 7B1 55 Special Tools (4 2) .......................................................................................................... 7B1 62

Rear Oil Seal (4 2)

Legend (1) Rear Propeller Shaft

(2) Rear Oil Seal

MANUAL TRANSMISSION 5. Remove grommet assembly (4).

Legend (1) Bolt (2) Nut (3) Fuel Pipe Assembly

MANUAL TRANSMISSION 14. Support transmission with a transmission jack.

13. Remove slave cylinder (10) and put aside it.

MANUAL TRANSMISSION C24NE

Legend (1) Bolt (2) Nut (3) Fuel Pipe Assembly

Legend (1) Grommet Assembly (2) Floor Panel (3) Front

7. Remove the fulcrum bridge from the transmission case. (6VE1)

Legend (1) Fulcrum bridge

Legend (1) Fulcrum bridge

Inspection and Repair

Shift Arm Thickness

Limit 9.0 mm (0.354 in)

Detent Spring Tension

Detent Spring Free Length

Detent Spring Free Length Standard 26.8 mm (1.06 in)

Limit 26.2 mm (1.03 in)

Limit 27.0 mm (1.06 in) 26.0 mm (1.02 in)

Legend (1) Warped

Reverse Gear and 5th Gear

10. Remove counter reverse gear (19).

The bearing snap ring (29) will come free.

Inspection and Repair

MANUAL TRANSMISSION 19. Install the bearing snap ring (1).

Inspection and Repair

Block Ring and Dog Teeth Clearance

1st-2nd Synchronizer (3-CONE)

Clutch Hub and Insert Clearance

Block Ring and Insert Clearance

Reverse Idler Gear and Idler Gear Shaft Clearance

Gear Inside Diameter

Clutch Hub Spline Play

Ball Bearing Play

MANUAL TRANSMISSION Use bearing installer 5-8840-2194-0 to install the ring.

Color Coding White Yellow Blue

Main Data and Specifications

About arrow mark, refer to Transmission (MUA) Installation in this section.

Torque Specifications (Cont'd)

Torque Specifications (Cont'd)

Insufficient or improper gear oil

Replenish or replace the gear oil

Flywheel pilot bearing

Worn flywheel pilot bearing

Replace the flywheel pilot

Worn or broken bearing(s)

Replace the bearing(s)

Worn or scuffed gear tooth contact surfaces

Replace the gear(s)

Realign the transmission

Gear oil (Metallic rattling)

Insufficient or improper engine oil

Replenish or replace the gear oil

OK Bearings (Hissing, thumping or bumping) NG

Worn or broken bearing(s)

Replace the bearing(s)

Gears (Growling, humming, or grinding)

Worn, chipped, or cracked gear(s)