07_TFMUA-WE-0431
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Transcript of 07_TFMUA-WE-0431
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WORKSHOP MANUAL
TF SERIES
MANUAL TRANSMISSION(MUA MODELS)
SECTION 7B1
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MANUAL TRANSMISSION 7B1-1
SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (42)
Service Precaution .......................................................................................................... 7B1 3
General Description ........................................................................................................ 7B1 4
Rear Oil Seal (42) ........................................................................................................... 7B1 5Transmission (42) ......................................................................................................... 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 42Reassembly ................................................................................................................. 7B1 45
Main Data and Specifications ......................................................................................... 7B1 51
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7B1-2 MANUAL TRANSMISSIONTroubleshooting............................................................................................................... 7B155
Special Tools (42) .......................................................................................................... 7B162
MUA (44)
Service Precaution .......................................................................................................... 7B163
General Description ........................................................................................................ 7B164
Transmission (44) ......................................................................................................... 7B165
Disassembled View..................................................................................................... 7B165
Removal ....................................................................................................................... 7B166
Installation ................................................................................................................... 7B170
Transmission Case .......................................................................................................... 7B177
Major Component ........................................................................................................ 7B177
Disassembly ................................................................................................................ 7B178
Reassembly ................................................................................................................. 7B179
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B182
Disassembled View..................................................................................................... 7B182
Disassembly ................................................................................................................ 7B183Inspection and Repair................................................................................................. 7B183
Reassembly ................................................................................................................. 7B184
Reverse Gear and 5th Gear ............................................................................................ 7B185
Disassembled View..................................................................................................... 7B185
Disassembly ................................................................................................................ 7B186
Inspection and Repair................................................................................................. 7B188
Reassembly ................................................................................................................. 7B188
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B194
Disassembled View..................................................................................................... 7B194
Disassembly ................................................................................................................ 7B196
Inspection and Repair.............................................................................................. 7B198
Reassembly .............................................................................................................. 7B1101
Main Data and Specifications ..................................................................................... 7B1107
Troubleshooting ........................................................................................................... 7B1111
Special Tools (44) ...................................................................................................... 7B1118
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MANUAL TRANSMISSION 7B1-3Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRSCOMPONENT 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 outthe 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.
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7B1-4 MANUAL TRANSMISSIONGeneral DescriptionMUA Transmission (42)
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.
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MANUAL TRANSMISSION 7B1-5Rear Oil Seal (42)
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 5-8522-
0050-0.
220RS044
2. Insert the splined yoke into the transimissionmainshaft spline.
3. Install the propeller shaft flange yoke to the drive
pinion flange.
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7B1-6 MANUAL TRANSMISSIONTorque : 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.
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MANUAL TRANSMISSION 7B1-7Transmission (42)
Disassembled View
RTW47BLF000701
Legend(1) Gear Control Lever Knob (10) Slave Cylinder
(2) Rear Floor Console (bucket seat) (11) Nut : rear mount to Crossmember
(3) Front Floor Console (12) Transmission Crossmember
(4) Grommet Assembly (13) Nut : rear mount to transmission
(5) Gear Control Lever (14) Rear Mount Rubber
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe (6VE1 only) (17) Transmission Assembly
(9) Fuel Pipe Bracket
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7B1-8 MANUAL TRANSMISSIONRemoval
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.
745R300006Legend(1) Knob
(2) Rear Floor Console(3) Front Floor Console
5. Remove grommet assembly (4).
RTW47BMH000101
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MANUAL TRANSMISSION 7B1-96. 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 thedifferential side.
401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)
150R300003
10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the
transmission.
Neutral Switch
Back up Switch
Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012Legend(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
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7B1-10 MANUAL TRANSMISSION
6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it.
Diesel engine
220LV019
6VE1
206RW002
14. Support transmission with a transmission jack.
220RS001
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.
220R300029Legend(1) Transmission
(2) Nut : rear mount to transmission
(3) Rear Mount Rubber
(4) Nut : rear mount to crossmember
(5) Transmission Crossmember
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MANUAL TRANSMISSION 7B1-1117. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.
501R300008
18. Take out the rear mount rubber (14).
19. Remove starter (15) (Diesel engine only).
060L100070
20. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
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.
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7B1-12 MANUAL TRANSMISSIONNOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064
220RW019Legend(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
1. Apply a thin coat of molybdenum disulfide grease tothe 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.
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MANUAL TRANSMISSION 7B1-134. Install the transmission assembly (17) to the engine.
Tighten the transmission nuts and bolts (16) as
shown in the figure.
Diesel engine
RTW37BLF000901
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7B1-14 MANUAL TRANSMISSION6VE1
RTW37BLF0001
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MANUAL TRANSMISSION 7B1-15C24NE
RTW37BLF0002
220RS006
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 releasebearing. (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.
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7B1-16 MANUAL TRANSMISSION6. 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 Nm (7.7 kgm/56 lbft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
Torque: 52 Nm (5.3 kgm/38 lbft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 Nm (6.8 kgm/49 lbft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).Torque: 52 Nm (5.3 kgm/38 lbft)
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 Nm (7.7 kgm/56 lbft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 Nm (7.7 kgm/56 lbft)
Nut 37 Nm (3.8 kgm/28 lbft)
Diesel engine
220R300012Legend(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
6VE1, C24NE
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 Nm (6.8 kgm/49 lbft)
150R300003
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MANUAL TRANSMISSION 7B1-1714. Install the exhaust pipe (8). (6VE1)
Torque: 67 Nm (6.8 kgm/49 lbft)
RTW37ASH000101
15. Install rear propeller shaft (6).
Torque: 63 Nm (6.4 kgm/46 lbft)
16. Install center bearing on crossemember.
Torque: 69 Nm (7.0 kgm/51 lbft)
17. Install gear control lever (5).
Torque: 19 Nm (1.9 kgm/14 lbft)
18. Install grommet assembly (4).Torque: Screw 1.4 Nm (0.14 kgm/12 lbin)
Nut 7 Nm (0.7 kgm/61 lbin)
RTW47BMH000101Legend(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 Nm (0.9 kgm/78 lbin)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
21. Connect battery ground cable.
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7B1-18 MANUAL TRANSMISSIONTransmission Case
Major Component
RTW37BLF0005
Legend(1) Gear Control Box Assembly and Gasket (9) Front Cover (with Oil Seal)
(2) Speedometer Sensor and Driven Gear (10) Top Gear Bearing Snap Ring
(3) Rear Cover Assembly (11) Release Bearing : C24NE
(4) Intermediate Plate with Gear Assembly (12) Shift Fork : C24NE
(5) Transmission Case (13) Fulcrum Bridge : 6VE1
(6) Release Bearing (with Spring) : Diesel engine (14) Release Bearing : 6VE1
(7) Shift Fork : Diesel engine (15) Shift Fork : 6VE1
(8) Counter Front Bearing Snap Ring
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MANUAL TRANSMISSION 7B1-19Disassembly
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)
RTW47BSH000601Legend(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002Legend(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.
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).
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7B1-20 MANUAL TRANSMISSION13. 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).
Reassembly1. 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.
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 Nm (2.0 kgm/14 lbft)
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 Nm (1.5 kgm/11 lbft)
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MANUAL TRANSMISSION 7B1-217. Install the speedometer sensor (2).
Torque: 27 Nm (2.8 kgm/20 lbft)
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 outercircumference.
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.
220R3000020
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 recommendedliquid gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six front cover bolts to the specified torque.
Torque: 25 Nm (2.6 kgm/19 lbft)
11. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (7).
(Diesel engine, C24NE)
F07L100026
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7B1-22 MANUAL TRANSMISSION12. Install the fulcrum bridge to the transmission case.
(6VE1)
Torque: 38 Nm (3.9 kgm/28 lbft)
RTW37ASH0002Legend(1) Fulcrum bridge
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)
15. Install the washer and snap pin. (6VE1)
RTW47BMH000201
16. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide typegrease as shown in the figure.
A07RW075
17. Install the release bearing (6) on the front cover,
joining it to the shift frok.
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MANUAL TRANSMISSION 7B1-23Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock PinDisassembled View
RTW47BLF000501
Legend(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly
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7B1-24 MANUAL TRANSMISSIONDisassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent ballsfrom 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.
230RS003
Use a spring pin remover to remove the shift
arm spring pins from the shift arms and the shift
rods.
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.
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).
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MANUAL TRANSMISSION 7B1-25Inspection and RepairMake 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 Limit
1st-2nd9.60 - 9.85 mm
(0.378 - 0.388 in)
3rd-4th
Rev.5th
9.60 - 9.80 mm
(0.378 - 0.386 in)
9.0 mm
(0.354 in)
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 Limit
26.8 mm (1.06 in) 26.2 mm (1.03 in)
SOUTH AFRICA 5th-Rev Only
Detent Spring Free Length
Standard Limit
Outer 27.6 mm (1.09 in) 27.0 mm (1.06 in)
Inner 26.6 mm (1.05 in) 26.0 mm (1.02 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 Standard
20 mm (0.787 in)87.2 - 97.1 N
(19.6 - 21.8 lb)
220RS013
SOUTH AFRICA 5th-RV OnlyDetent Spring Free Length
Compressed Standard
Outer 20 mm (0.787 in)93.5 103.3 N
(21.0 23.3 lb)
Inner 20 mm (0.787 in)26.4 36.3 N
(5.9 8.2 lb)
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7B1-26 MANUAL TRANSMISSIONReassembly
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.
230RS007
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 andgasket (1).
Install a new gasket and the detent spring plate.
Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 Nm (2.5 kgm/18 lbft)
220RS030Legend(1) Warped
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MANUAL TRANSMISSION 7B1-27Reverse Gear and 5th Gear
Disassembled View
226R300027
Legend(1) Bearing Snap Ring (11) Reverse Idler Gear Assembly
(2) Ball Bearing (12) Idle Shaft Pin
(3) Bearing Snap Ring (13) Thrust Washer
(4) Speedometer Drive Gear (14) Reverse Idler Gear
(5) Clip (15) Reverse Idler Shaft
(6) Retainer Snap Ring (16) Bearing Snap Ring
(7) Retainer (17) Ball Bearing
(8) Thrust Plate (18) Counter 5th Gear
(9) Thrust Washer and Lock Ball (19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring (20) 5th Gear
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7B1-28 MANUAL TRANSMISSION(21) 5th Block Ring (26) Reverse Gear
(22) Needle Bearing (27) Needle Baring
(23) Mainshaft Nut (28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly (29) Bearing Snap Ring
(25) Reverse Block Ring (30) Intermediate Plate
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MANUAL TRANSMISSION 7B1-29Disassembly
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 puller5-8840-2027-0 to the bearing (2) and the mainshaft
end to remove the ball bearing (2).
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 lockball (9).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (10).
226RS004
6. Remove the reverse idler gear assembly (11) from
the intermediate plate (30).
226RS005
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).
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7B1-30 MANUAL TRANSMISSION11. Remove 5th gear (20), 5th block ring (21), and
needle bearing (2 piece type) (22).
226RS007
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.
226RW212
Engage the 3rd-4th synchronizer with the 3rd
gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
226RW210
Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut (23).
226RW211
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MANUAL TRANSMISSION 7B1-3113. 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).
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.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).
226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate (30) toward the rear of
the transmission to remove it.
The bearing snap ring (29) will come free.
Inspection and Repair
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.
226RW212
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7B1-32 MANUAL TRANSMISSION2. 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 Nm (1.5 kgm/11 lbft)
220RW137
4. Install needle bearing (27), reverse gear (26), and
reverse block ring (25).
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.
226RS013
226RS049
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MANUAL TRANSMISSION 7B1-336. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).
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 Nm (14 kgm/101 lbft)
226RW214
8. Use a punch to stake the mainshaft nut (23).
226RW153
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.
226RW151
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7B1-34 MANUAL TRANSMISSION11. 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.
226RS020
There are six snap ring sizes available.
The snap rings are color‐coded to indicate
their thickness.
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.
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MANUAL TRANSMISSION 7B1-3514. Select reverse idler gear snap ring (10) which will
provide the minimum clearance between the
intermediate plate (30) and the snap ring (10).
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 Coding1.2 mm (0.047 in) White
1.3 mm (0.051 in) Yellow
1.4 mm (0.055 in) Blue
226RS021
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.
226RS023
Select appropriate thrust washer from chart.
There are four thrust washer sizes available.
Thrust Washer Availability
Thickness
mm (in)
Color
CodingA mm (in)
Clearance
mm (in)
7.9 (0.311) White8.05 - 8.1
(0.317-0.319)
0.15 - 0.25
(0.006-0.010)
8.0 (0.315) Yellow8.1 - 8.2
(0.319-0.323)
0.1 - 0.25
(0.004-0.010)
8.1 (0.319) Green8.2 - 8.3
(0.323-0.327)
0.1 - 0.25
(0.004-0.010)
8.2 (0.323) Blue8.3 - 8.36
(0.327-0.329)
0.1 - 0.21
(0.004-0.008)
The thrust washers are color coded to indicate
their thickness as shown in the figure.
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7B1-36 MANUAL TRANSMISSION
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 ballbearing (2) to the mainshaft.
226L100002
19. Install the bearing snap ring (1).
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MANUAL TRANSMISSION 7B1-37Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
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7B1-38 MANUAL TRANSMISSIONLegend
(1) Top Gear Shaft Snap Ring (16) 1st Outside Ring
(2) Top Gear Shaft (17) 1st Block Ring
(3) Ball Bearing (18) Needle Bearing
(4) Needle Bearing (19) Clutch Hub Snap Ring
(5) Top Block Ring (20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring (21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly (22) 2nd Outside Ring
(8) 3rd Block Ring (23) 2nd Inside Ring
(9) 3rd Gear (24) 2nd Gear
(10) Needle Bearing (25) Needle Bearing
(11) Needle Bearing Collar (26) Mainshaft
(12) Mainshaft Ball Bearing (27) Bearing Snap Ring(13) 1st Gear Thrust Bearing (28) Front Roller Bearing
(14) 1st Gear (29) Center Roller Bearing
(15) 1st Inside Ring (30) Counter Gear Shaft
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MANUAL TRANSMISSION 7B1-39Disassembly
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 5-8840-
0015-0 to remove the ball bearing(3).
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).
226RS008
6. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
Disassemble the synchronizer assembly.
226RW217Legend(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needlebearing (10).
8. Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RW218
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7B1-40 MANUAL TRANSMISSION9.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 5-8840-
0015-0 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.
226RW220Legend(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
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.
226RW219
16. Remove center roller bearing (29) from counter gearshaft (30).
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MANUAL TRANSMISSION 7B1-41Inspection and RepairMake 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 ClearanceStandard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
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7B1-42 MANUAL TRANSMISSION1st-2nd Synchronizer (3-CONE)
Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.032 in)
Block Ring and Insert Clearance
Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.
226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.
Block and Insert Clearance
Standard Limit
3rd-4th3.46 - 3.76 mm
(0.136 - 0.148 in)
4.0 mm
(0.158 in)
1st-2nd3.86 4.16 mm
(0.152 - 0.164 in)
4.9 mm
(0.193 in)
Rev.5th3.59 - 3.91 mm
(0.141 - 0.154 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.
226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance
Standard Limit
1st-2nd
3rd-4th
0.01 0.21 mm
(0.004 - 0.0083 in)
0.3 mm
(0.012 in)
Rev-5th0.09 0.31 mm
(0.0035 - 0.0122 in)
0.4 mm
(0.016 in)
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MANUAL TRANSMISSION 7B1-43Mainshaft Run-out
Install the mainshaft to V-blocks.
Use a dial indicator to measure the mainshaft
central portion run-out.
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.
226RS040
If the measured value is less than the specified limit,
the gear must be replace.
Gear Inside Diameter
Standard Limit
1st
3rd
45.000 - 45.013 mm
(1.771 - 1.772 in)
45.100 mm
(1.776 in)
2nd52.000 - 52.013 mm
(2.047 - 2.048 in)
52.100 mm
(2.051 in)
Rev.48.000 - 48.013 mm
(1.889 - 1.890 in)
48.100 mm
(1.894 in)
5th32.000 - 32.013 mm
(1.259 - 1.260 in)
32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear ShaftClearance
Use a micrometer to measure the idler gear shaft
diameter.
Use an inside dial indicator to measure the idlergear 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)
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7B1-44 MANUAL TRANSMISSIONClutch Hub Spline Play
Set a dial indicator to the clutch hub to be
measured.
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 Limit
1st-2nd
3rd-4th
0 - 0.1 mm
(0 - 0.004 in)
0.2 mm
(0.008 in)
Rev. 5th0 - 0.2 mm
(0 - 0.008 in)
0.3 mm
(0.012 in)
Ball Bearing Play
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS043
Reassembly
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.
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 thetransmission front side.
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MANUAL TRANSMISSION 7B1-45 Use bearing installer 5-8840-2194-0 to install the
ring.
RTW47BSH000501Legend(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.
226RS046
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.
226RS047Legend(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing6. 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.
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7B1-46 MANUAL TRANSMISSION
266RS049
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.
226RS048
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.
226RS050
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.
226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) 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.
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MANUAL TRANSMISSION 7B1-47
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.
226RS053Legend(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
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.
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.
226RS055
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7B1-48 MANUAL TRANSMISSION12. 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.
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 theclutch 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.
226RW221
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.
226RS058
There are three snap ring sizes available.
The snap rings are color coded to indicate their
thickness as shown in the figure.
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MANUAL TRANSMISSION 7B1-49
226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) White
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
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.
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).
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).
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7B1-50 MANUAL TRANSMISSIONMain Data and SpecificationsGeneral Specifications
MUA 5G MUA 5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"
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MANUAL TRANSMISSION 7B1-51Torque Specifications
RTW47BLF001201
About arrow mark, refer to Transmission (MUA) Installation in this section.
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7B1-52 MANUAL TRANSMISSIONTorque Specifications (Cont'd)
RTW47BLF000901
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MANUAL TRANSMISSION 7B1-53Torque Specifications (Cont'd)
RTW47BLF000601
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7B1-54 MANUAL TRANSMISSIONTROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Checkpoint Trouble Cause Countermeasure
Replenish or replace the gear
oil
Insufficient or improper gear
oil
NG
Mainshaft splines
Synchronizer clutch hub
splines
Replace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
Worn splines
Worn or scuffed gear tooth
contact surfaces
Flywheel pilot bearing Worn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)Worn or broken bearing(s)
OK
NG
NG
NG
NG
OK
OK
OK
Gear oil
Transmission Realign the transmissionTransmission misalignment
OK
NG
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MANUAL TRANSMISSION 7B1-552) NOISY OPERATION
Checkpoint Trouble Cause Countermeasure
Replenish or replace the gear
oil
Insufficient or improper engine
oil
NG
Replace the gear(s)
Replace the gear(s)
Replace the bearing(s)
Gears (Gear whining)Lack of backlash between
meshing gears
Free running gears seizing on
the thrust face or the innerface
Bearings (Hissing, thumping
or bumping)Worn or broken bearing(s)
Gears (Squealing at high
speeds)
Replace the gear(s)Gears (Growling, humming, or
grinding)
Worn, chipped, or cracked
gear(s)
NG
NG
NG
NG
OK
OK
OK
OK
Gear oil (Metallic rattling)
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7B1-56 MANUAL TRANSMISSION2. HARD SHIFTING
Checkpoint Trouble Cause Countermeasure
Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OK
NG
NG
NG
NG
OK
OK
Gear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other parts
Replace the shidt rod and/or
the quadrant box
Worn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG
NG
OK
Shift block sleeve movement
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MANUAL TRANSMISSION 7B1-57Checkpoint Trouble Cause Countermeasure
Synchronizer assembly
Shift arm and synchronizer
sleeve
Replace the worn parts
Replace the worn parts
Worn synchronizer parts
Worn shift arm and/or
synchronizer sleeve groove
Mainshaft and countershaft
thrust playReplace the worn parts
Worn thrust washer, collar,
and/or gear thrust faces
OK
NG
NG
NG
OK
OK
Continued from the previous
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7B1-58 MANUAL TRANSMISSION3. WALKING OR JUMPING OUT OF GEAR
Checkpoint Trouble Cause Countermeasure
Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent springRepair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OK
NG
NG
NG
NG
OK
OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust play Replace the worn parts
Worn thrust washer, collar,
and/or gear thrust faces
Replace the worn partsWorn shift arm and/or
synchronizer sleeve groove
NG
NG
OK
Shift arm and synchronizer
sleeve
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MANUAL TRANSMISSION 7B1-59Checkpoint Trouble Cause Countermeasure
Synchronizer assembly
Bearings (Mainshaft,
countershaft, and individual
gears)
Replace the spring
Replace the bearing(s)
Weak or broken spring
Worn or broken bearings(s)
Mainshaft splines
Synchronizer clutch hub
splines
Replace the main shaft and
the synchronizer clutch hubWorn splines
OK
NG
NG
NG
OK
OK
Continued from the previous page
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7B1-60 MANUAL TRANSMISSION4. OIL LEAKAGE
Checkpoint Trouble Cause Countermeasure
Gear oil Replace the gear oilImproper gear oil
Drain plug and/or filler plugTighten the plug(s) and
replenish the oil
Drain the oil to the correct
level
Loose plug(s)
Oil level too high
OK
NG
NG
NG
OK
OK
Oil level
Rear cover oil seal
Air breather
Replace the oil seal
Install the air breather
Replace the air breather
Worn or scratched oil seal
Air breather not installed
Air breather clogged
Front cover oil seal Replace the oil seal
Replace the gasket(s)
Worn or scratched oil seal
Defective or improperly
installed gasket(s)
OK
NG
NG
NG
NG
OK
OK
Gaskets
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MANUAL TRANSMISSION 7B1-61Special Tools (42)
ILLUSTRATIONTOOL NO.
TOOL NAME
ILLUSTRATIONTOOL NO.
TOOL NAME
5-8840-2155-0
Bearing remover
5-8840-2159-0
Mainshaft end bearing
installer
5-8840-2027-0
Puller
5-8840-0015-0Bearing
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
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7B1-62 MANUAL TRANSMISSIONService Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRSCOMPONENT 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 outthe 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.
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MANUAL TRANSMISSION 7B1-63General DescriptionMUA Transmission (44)
A07R300003
The MUA is a constant mesh transmission,
synchronized in all speeds. The transmission isdesigned 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 thegears.
The transmission control box is built into the
transmission.
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7B1-64 MANUAL TRANSMISSIONTransmission (44)
Disassembled View
RTW47BLF001001
Legend(1) Gear Control Lever Knob (10) Transmission-Transfer Fixing Bolt
(2) Rear Floor Console (bucket) (11) Transfer Assembly
(3) Front Floor Console (12) Fuel Pipe Bracket
(4) Grommet Assembly (13) Slave Cylinder
(5) Gear Control Lever (14) Rear Mount Nut
(6) Rear Propeller Shaft (15) Transmission Crossmember
(7) Front Propeller Shaft (16) Starter (Diesel engine only)
(8) Exhaust Pipe Nut (Diesel engine) (17) Transmission Retaining Nut and Bolt
(9) Exhaust Pipe Assembly (6VE1) (18) Transmission Assembly
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MANUAL TRANSMISSION 7B1-65Removal
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.
745R300006Legend(1) Knob
(2) Rear Floor Console(3) Front Floor Console
5. Remove grommet assembly (4).
RTW47BMH000101
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7B1-66 MANUAL TRANSMISSION6. 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 thedifferential side.
9. Remove front propeller shaft (7).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
401RS023
10. Loosen the front exhaust pipe fixing nuts (8) at the
engine side but not remove them. (Diesel engineonly)
150R300004
11. Remove the exhaust pipe (9). (6VE1 only)
RTW37ASH000101
12. Disconnect harness connectors and clips on the
transfer.
Actuator connector
Car Speed Sensor
810R300069Legend(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
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MANUAL TRANSMISSION 7B1-6713. 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).
Diesel engine
220R300012Legend(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
6VE1, C24NE
Scan-2
16. Remove slave cylinder (13) and put aside it.
220LV019
17. Support transmission with a transmission jack.
220RS0001
18. Remove engine rear mount nuts (14) from
transmission crossmember (15).
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7B1-68 MANUAL TRANSMISSION19. Remove engine rear mount bolts fixing
transmission.
220R300009
20. Remove the middle part of transmission
crossmember (15) by removing four fixing bolts and
nuts.
501R30007
21. Take out the rear support rubber.
22. Remove starter (16). (Diesel engine only)
060L100070
23. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
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.
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MANUAL TRANSMISSION 7B1-69NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064
220RW019Legend(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.
Installation1. 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.
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7B1-70 MANUAL TRANSMISSION4. Install the transmission assembly (18) to the engine.
Tighten the transmission nuts and bolts as shown in
the figure.
Diesel engine
RTW37BLF000901
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MANUAL TRANSMISSION 7B1-716VE1
RTW37BLF0001
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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
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MANUAL TRANSMISSION 7B1-736. 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 Nm (7.7 kgm/56 lbft)
7. Install the rear support rubber on the transmission
and tighten the bolts to the specified torque.
Torque: 50 Nm (5.1 kgm/37 lbft)
8. Install the middle part of transmission crossmember
(15) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 Nm (6.8 kgm/49 lbft)
9. Install engine rear mount nuts (14).
Torque: 52 Nm (5.3 kgm/38 lbft)
Remove the transmission jack from transmissionside.
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 Nm (7.7 kgm/56 lbft)
11. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe
brackets
Torque: Bolt & Nut 76 Nm (7.7 kgm/56 lbft)
Nut 37 N
m (3.8 kg
m/28 lb
ft)
Diesel engine
220R300012Legend(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
6VE1, C24NE
Scan-2
12. Connect transmission harness connectors and clips.
Connector: transfer neutral switch, 2W - 4W switch,
backup switch, transmission neutral switch.
810R300069Legend(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.
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7B1-74 MANUAL TRANSMISSION15. Install the transmission-transfer bolts and nut and
tighten them to the specified torque.
Torque: 41 Nm (4.2 kgm/30 lbft)
261R300005
18. Install the exhaust pipe (9). (6VE1)
Torque: 67 Nm (6.8 kgm/49 lbft)
RTW37ASH000101
19. Install front propeller shaft (7).
Refer to the section Front Propeller Shaft.
20. Install rear propeller shaft (6).
Torque: 63 Nm (6.4 kgm/46 lbft)
21. Install the center bearing on crossmember.
Torque: 69 Nm (7.0 kgm/51 lbft)
22. Install gear control lever (5).Torque: 19 Nm (1.9 kgm/14 lbft)
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MANUAL TRANSMISSION 7B1-7521. Install grommet assembly (4).
Torque: Screw 1.4 Nm (0.14 kgm/12 lbin)
Nut 7 Nm (0.7 kgm/61 lbin)
RTW47BMH000101Legend(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 Nm (0.9 kgm/78 lbin)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
26. Connect battery ground cable.
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7B1-76 MANUAL TRANSMISSIONTransmission Case
Major Component
RTW47BLF000101
Legend(1) Gear Control Box Assembly and Gasket (8) Front Cover (with Oil Seal)
(2) Rear Case Assembly (9) Top Gear Bearing Snap Ring
(3) Intermediate Plate with Gear Assembly (10) Release Bearing : C24NE
(4) Transmission Case (11) Shift Fork : C24NE
(5) Release Bearing (with Spring): 4JH1-TC (12) Fulcrum Bridge : 6VE1
(6) Shift Fork: 4JH1-TC (13) Release Bearing : 6VE1
(7) Counter Front Bearing Snap Ring (14) Shift Fork : 6VE1
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MANUAL TRANSMISSION 7B1-77Disassembly
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)
RTW47BSH000601Legend(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002Legend(1) Fulcrum bridge
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.
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).
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7B1-78 MANUAL TRANSMISSIONRear Oil Seal Replacement
220R300025Legend(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 5-
8840-0007-0 to install the oil seal to the rear case.
Reassembly1. 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 Nm (3.8 kgm/27 lbft)
220R300026
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 Nm (2.0 kgm/14 lbft)
261R300004
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MANUAL TRANSMISSION 7B1-795. 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.
220R3000020
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 Nm (3.9 kgm/28 lbft)
RTW37ASH0002Legend(1) Fulcrum bridge
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)
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7B1-80 MANUAL TRANSMISSION12. 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 typegrease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover,
joining it to the shift fork.
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MANUAL TRANSMISSION 7B1-81Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock PinDisassembled View
RTW47BLF000501
Legend(1) Detent Spring Plate and Gasket (7) 1st-2nd Shift Rod
(2) Detent Spring (8) 3rd-4th Shift Rod
(3) Detent Ball (9) 3rd-4th Shift Arm
(4) Spring (10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod (11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor (12) Intermediate Plate and Gear Assembly
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7B1-82 MANUAL TRANSMISSIONDisassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent ballsfrom 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.
230RS003
Use a spring pin remover to remove the shift
arm spring pins from the shift arms and the shift
rods.
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.
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).
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7B1-84 MANUAL TRANSMISSIONReassembly
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.
230RS007
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 andgasket (1).
Install a new gasket and the detent spring plate.
Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 Nm (2.5 kgm/18 lbft)
220RS030Legend(1) Warped
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MANUAL TRANSMISSION 7B1-85Reverse Gear and 5th Gear
Disassembled View
226R300024
Legend(1) Collar Snap Ring (15) Counter 5th Gear
(2) Oil Seal Collar (16) Counter Reverse Gear
(3) Ball Bearing (17) 5th Gear
(4) Retainer (18) 5th Block Ring
(5) Thrust Plate (19) Needle Bearing
(6) Thrust Washer and Lock Ball (20) Mainshaft Nut
(7) Reverse Idler Gear Snap Ring (21) Rev-5th Synchronizer Assembly
(8) Reverse Idler Gear Assembly (22) Reverse Block Ring
(9) Idle Shaft Pin (23) Reverse Gear
(10) Thrust Washer (24) Needle Baring
(11) Reverse Idler Gear (25) Bearing Plate and Screw
(12) Reverse Idler Shaft (26) Bearing Snap Ring
(13) Bearing Snap Ring (27) Intermediate Plate
(14) Ball Bearing
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7B1-86 MANUAL TRANSMISSIONDisassembly
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 andpuller 5-8840-2027-0 to the retainer (4) and the
mainshaft end.
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).
226RS004
6. Remove the reverse idler gear assembly (8) from
the intermediate plate (27).
226RS005
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).
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MANUAL TRANSMISSION 7B1-8711. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).
226RS007
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.
226RW212
Engage the 3rd-4th synchronizer with the 3rd
gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
226RW210
Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut (20).
226RW211
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7B1-88 MANUAL TRANSMISSION13. 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).
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.
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16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).
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17. Hold the snap ring open with the pliers.
Push the intermediate plate (27) toward the rear of
the transmission to remove it.
The bearing snap ring will come free.
Inspection and Repair
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.
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MANUAL TRANSMISSION 7B1-892. 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 Nm (1.5 kgm/11 lbft)
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4. Install needle bearing (24), reverse gear (23), and
reverse block ring (22).
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.
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7B1-90 MANUAL TRANSMISSION6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).
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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 Nm (14 kgm/101 lbft)
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8. Use a punch to stake the mainshaft nut (20).
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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.
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MANUAL TRANSMISSION 7B1-9111. Install the counter 5th gear (15) to the counter shaft.
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12. Install ball bearing (14) and bearing snap ring (13)
by performing the following steps:
Select the snap ring which will provide the
minimum cl