Isuzu Manual Transmission MUA Models Isuzu Manual Transmission MUA Models

WORKSHOP MANUAL

TF SERIES

MANUAL TRANSMISSION

(MUA MODELS)

SECTION 7B1

MANUAL TRANSMISSION 7B1-1

SECTION 7B1

TRANSMISSION

MANUAL TRANSMISSION MUA

CONTENTS

PAGE

MUA (4

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

´´´´

2)

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

MUA (4

´´´´

4)

2) .......................................................................................................... 7B1 –62

´´´´

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)

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.

A07R300006

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

Disassembled View

Rear Oil Seal (4

´´´´

2)

Legend

Removal

1. Raise and support vehicle with suitable jack stands.

2. Remove propeller shaft flange yoke bolts and nuts

3. Remove center bearing from crossmenber.

4. Remove prepeller shaft from the transmission main

Refre to the section “Rear Propeller Shaft”.

5. Use a screwdriver to pry the rear oil seal from the

(1) Rear Propeller Shaft (2) Rear Oil Seal

at the differential side.

shaft spline.

rear cover.

Installation

1. Install a new oil seal (2) using the installer 5-8522­0050-0.

2. Insert the splined yoke into the transimission

3. Install the propeller shaft flange yoke to the drive

mainshaft spline.

pinion flange.

220R300030

220RS044

7B1-6 MANUAL TRANSMISSION

Torque : 63 N·m (6.4 kg·m/46 lb·ft)

4. Install center bearing on crossmember.

Torque : 69 N·m (7.0 kg·m/51 lb·ft)

5. Check transmission fluid level.

6. Lower vehicle.

MANUAL TRANSMISSION 7B1-7

Disassembled View

Transmission (4

´´´´

2)

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

RTW47BLF 000701

7B1-8 MANUAL TRANSMISSION

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).

Legend

(1) Knob
(2) Rear Floor Console
(3) Front Floor Console

745R300006

RTW47BM H000101

MANUAL TRANSMISSION 7B1-9

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.

401RS023

9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)

10. Remove the exhaust pipe (8). (6VE1 only)

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

RTW37ASH0001

150R300003

Legend

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

220R300012

7B1-10 MANUAL TRANSMISSION

6VE1, C24NE

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

Diesel engine

14. Support transmission with a transmission jack.

Scan-1

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.

6VE1

220LV019

206RW002

Legend

(1) Transmission
(2) Nut : rear mount to transmission
(3) Rear Mount Rubber
(4) Nut : rear mount to crossmember
(5) Transmission Crossmember

220R300029

MANUAL TRANSMISSION 7B1-11

17. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.

18. Take out the rear mount rubber (14).

19. Remove starter (15) (Diesel engine only).

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

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.

220RW109

060L100070

7B1-12 MANUAL TRANSMISSION

NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.

220RW063

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

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.

220RW019

220RW064

MANUAL TRANSMISSION 7B1-13

4. Install the transmission assembly (17) to the engine.
Tighten the transmission nuts and bolts (16) as

shown in the figure.

Diesel engine

RTW37BLF 000901

7B1-14 MANUAL TRANSMISSION

6VE1

RTW37BLF 0001

C24NE

MANUAL TRANSMISSION 7B1-15

RTW37BLF 0002

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

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 76 Nm (7.7 kgm/56 lbft)

Nut 37 N



m (3.8 kg



m/28 lb



ft)

6VE1, C24NE

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)

Scan-1

Diesel engine

Legend

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

150R300003

220R300012

14. Install the exhaust pipe (8). (6VE1)

Torque: 67 Nm (6.8 kgm/49 lbft)

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 1.4 Nm (0.14 kgm/12 lbin)

Nut 7 Nm (0.7 kgm/61 lbin)

RTW37AS H000101

MANUAL TRANSMISSION 7B1-17

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.

RTW47BM H000101

7B1-18 MANUAL TRANSMISSION

Major Component

Transmission Case

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

RTW37BLF 0005

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)

Legend

(1) Shift fork pin

(2) Shift fork
(3) Release bearing

RTW47BS H000601

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

RTW37AS H0002

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.

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

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.

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)

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 7B1-21

7. Install the speedometer sensor (2).

Torque: 27 Nm (2.8 kgm/20 lbft)

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.

225R300001

·

Use the oil seal installer 5-8840-0026-0 to install

the oil seal to the front cover.

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)

220R3000020

F07L100026

7B1-22 MANUAL TRANSMISSION

12. Install the fulcrum bridge to the transmission case.
(6VE1)

Torque: 38 N

Legend



m (3.9 kg



m/28 lb



ft)

RTW37ASH0002

(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)

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.

RTW47BM H000201

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

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

RTW47BLF 000501

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.

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.

220RS011

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.

·

Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.

230RS003

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).

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 Limit

1st-2nd

3rd-4th

Rev.5th

9.60 - 9.85 mm

(0.378 - 0.388 in)

9.60 - 9.80 mm

(0.378 - 0.386 in)

9.0 mm

(0.354 in)

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)

220RS012

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)

230RS006

SOUTH AFRICA 5th-RV Only
Detent Spring Free Length

Compressed Standard

Outer 20 mm (0.787 in)

Inner 20 mm (0.787 in)

93.5 – 103.3 N

(21.0 – 23.3 lb)

26.4 – 36.3 N
(5.9 – 8.2 lb)

220RS013

7B1-26 MANUAL TRANSMISSION

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.

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)

Legend

(1) Warped

220RS030

230RS007

Disassembled View

Reverse Gear and 5th Gear

MANUAL TRANSMISSION 7B1-27

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

226R300027

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

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).

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).

6. Remove the reverse idler gear assembly (11) from
the intermediate plate (30).

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

262L100001

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).

226RS005

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).

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.

226RS007

226RW210

·

Use the mainshaft nut wrench 5-8840-2156-0 to

remove the mainshaft nut (23).

· Engage the 3rd-4th synchronizer with the 3rd

gear.

·

Engage the 1st-2nd synchronizer with the 1st

gear.

226RW211

226RW212

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).

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.

226RS010

MANUAL TRANSMISSION 7B1-31

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.

226RS011

220RW137

16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).

226RW212

7B1-32 MANUAL TRANSMISSION

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)

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.

4. Install needle bearing (27), reverse gear (26), and
reverse block ring (25).

220RW137

226RS013

226RS049

MANUAL TRANSMISSION 7B1-33

6. 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 Nm (14 kgm/101 lbft)

8. Use a punch to stake the mainshaft nut (23).

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.

226RW153

226RW214

226RW151

7B1-34 MANUAL TRANSMISSION

11. Install the counter 5th gear (18) to the counter shaft.

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.

226RS019

·

There are six snap ring sizes available.

The snap rings are color‐coded to indicate
their thickness.

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

226RS021

·

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

226RS020

faces to gear side.

MANUAL TRANSMISSION 7B1-35

14. Select reverse idler gear snap ring (10) which will
provide the minimum clearance between the
intermediate plate (30) and the snap ring (10).

·

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

226RS022

·

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.

·

Select appropriate thrust washer from chart.

·

There are four thrust washer sizes available.

Thrust Washer Availability

Thickness

mm (in)

7.9 (0.311) White

8.0 (0.315) Yellow

8.1 (0.319) Green

8.2 (0.323) Blue

Color

Coding

A mm (in)

8.05 - 8.1

(0.317-0.319)

8.1 - 8.2

(0.319-0.323)

8.2 - 8.3

(0.323-0.327)

8.3 - 8.36

(0.327-0.329)

Clearance

mm (in)

0.15 - 0.25

(0.006-0.010)

0.1 - 0.25

(0.004-0.010)

0.1 - 0.25

(0.004-0.010)

0.1 - 0.21

(0.004-0.008)

226RS023

·

The thrust washers are color coded to indicate

their thickness as shown in the figure.

226RS021

7B1-36 MANUAL TRANSMISSION

·

Apply grease to the thrust washer and the lock

226RS024

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.

19. Install the bearing snap ring (1).

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 (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

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).

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).

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.

Legend

226RW216

(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).

226RW217

226RS008

226RW218

7B1-40 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).

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.

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

16. Remove center roller bearing (29) from counter gear
shaft (30).

226RW219

Legend

(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

226RW220

MANUAL TRANSMISSION 7B1-41

Inspection and Repair

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.

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)

226RS035

7B1-42 MANUAL TRANSMISSION

1st-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 and Insert Clearance

Standard Limit

3rd-4th

1st-2nd

Rev.5th

3.46 - 3.76 mm

(0.136 - 0.148 in)

3.86 – 4.16 mm

(0.152 - 0.164 in)

3.59 - 3.91 mm

(0.141 - 0.154 in)

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.

Block Ring and Insert Clearance

· Use a vernier caliper or thickness gauge to measure

the clearance between the block ring and the insert.

If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.

226RS037

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

Rev-5th

0.01 – 0.21 mm

(0.004 - 0.0083 in)

0.09 – 0.31 mm

(0.0035 - 0.0122 in)

0.3 mm

(0.012 in)

0.4 mm

(0.016 in)

226RS038

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.

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.

226RS039

Gear Inside Diameter

Standard Limit

1st

3rd

2nd

Rev.

5th

45.000 - 45.013 mm
(1.771 - 1.772 in)

52.000 - 52.013 mm
(2.047 - 2.048 in)

48.000 - 48.013 mm
(1.889 - 1.890 in)

32.000 - 32.013 mm
(1.259 - 1.260 in)

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.

If the measured value is less than the specified limit,
the gear must be replace.

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

7B1-44 MANUAL TRANSMISSION

Clutch Hub Spline Play

· Set a dial indicator to the clutch hub to be
measured.

· 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

Rev. 5th

0 - 0.1 mm

(0 - 0.004 in)

0 - 0.2 mm

(0 - 0.008 in)

0.2 mm

(0.008 in)

0.3 mm

(0.012 in)

226RS042

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.

226RS043

Ball Bearing Play

· Use a dial indicator to measure the ball bearing play.

Ball Bearing Play

Limit: 0.2 mm (0.008 in)

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.

226RS044

MANUAL TRANSMISSION 7B1-45

·

Use bearing installer 5-8840-2194-0 to install the

ring.

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.

RTW47BSH000501

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.

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

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.

266RS049

226RS050

·

There are three snap ring sizes available.

· The snap rings are color coded to indicate their
thickness as shown in the figure.

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.

226RS048

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.

226RS021

MANUAL TRANSMISSION 7B1-47

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.

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

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.

226RS054

Legend

(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring

226RS053

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.

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.

226RS056

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.

226RS049

226RW221

226RS058

There are three snap ring sizes available.

The snap rings are color coded to indicate their
thickness as shown in the figure.

MANUAL TRANSMISSION 7B1-49

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).

226RS021

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).

7B1-50 MANUAL TRANSMISSION

Main Data and Specifications

General 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"

Torque Specifications

MANUAL TRANSMISSION 7B1-51

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

RTW47BLF 001201

7B1-52 MANUAL TRANSMISSION

Torque Specifications (Cont'd)

RTW47BLF 000901

Torque Specifications (Cont'd)

MANUAL TRANSMISSION 7B1-53

RTW47BLF 000601

7B1-54 MANUAL TRANSMISSION

Checkpoint Trouble Cause Countermeasure

TROUBLESHOOTING

1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Insufficient or improper gear

Gear oil

OK

Flywheel pilot bearing Worn flywheel pilot bearing

OK

Bearings (Mainshaft,
countershaft, and transfer
shaft)

OK

Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)

NG

oil

NG

NG

NG

Worn or scuffed gear tooth
contact surfaces

Replenish or replace the gear
oil

Replace the flywheel pilot

Replace the bearing(s)Worn or broken bearing(s)

Replace the gear(s)

OK

Mainshaft splines
Synchronizer clutch hub
splines

OK

Transmission

NG

NG

Worn splines

Replace the main shaft and
the synchronizer clutch hub

Realign the transmissionTransmission misalignment

MANUAL TRANSMISSION 7B1-55

2) NOISY OPERATION

Checkpoint Trouble Cause Countermeasure

Gear oil (Metallic rattling)

OK

Bearings (Hissing, thumping
or bumping)

OK

Gears (Growling, humming, or
grinding)

OK

Gears (Squealing at high
speeds)

Insufficient or improper engine

NG

oil

NG

Worn or broken bearing(s)

NG

Worn, chipped, or cracked
gear(s)

Free running gears seizing on

NG

the thrust face or the inner
face

Replenish or replace the gear
oil

Replace the bearing(s)

Replace the gear(s)

Replace the gear(s)

Gears (Gear whining)

OK

NG

Lack of backlash between
meshing gears

Replace the gear(s)

7B1-56 MANUAL TRANSMISSION

Checkpoint Trouble Cause Countermeasure

2. HARD SHIFTING

Gear oil

OK

Clutch pedal free play

OK

Change lever operation

OK

Change lever play

OK

NG

Insufficient or improper gear
oil

Improper clutch pedal free

NG

play

NG

Hard operating change lever
caused insufficient grease

NG

Worn change lever sliding
portions

Replenish or replace the
engine oil

Readjust the clutch pedal free
play

Repair or regrease the change
lever assembly

Repair or replace the
applicable parts and regrease

Shift block sleeve movement

OK

Shift rod and quadrant box
sliding faces, and other parts

Continued on the next page

NG

Worn shift rod and/or sliding

NG

faces

Repair or replace the sleeveSleeve movement failure

Replace the shidt rod and/or
the quadrant box

Checkpoint Trouble Cause Countermeasure

Continued from the previous

OK

MANUAL TRANSMISSION 7B1-57

Shift arm and synchronizer
sleeve

OK

Mainshaft and countershaft
thrust play

OK

Synchronizer assembly

Worn shift arm and/or

NG

synchronizer sleeve groove

NG

Worn thrust washer, collar,
and/or gear thrust faces

NG

Worn synchronizer parts

Replace the worn parts

Replace the worn parts

Replace the worn parts

7B1-58 MANUAL TRANSMISSION

3. WALKING OR JUMPING OUT OF GEAR

Checkpoint Trouble Cause Countermeasure

Change lever play

OK

NG

Insufficient stroke caused by
sliding position wear and
excessive play

Replace the worn parts

Detent ball

OK

Detent spring

OK

Shift rod and quadrant box
sliding faces

OK

Shift arm and synchronizer
sleeve

NG

Worn detent ball

NG

Detent spring weak or broken

NG

Worn shift rod and/or sliding
faces

NG

Worn shift arm and/or
synchronizer sleeve groove

Replace the detent ball

Repair or replace the detent
spring

Replace the shift rod and/or
the quadrant box

Replace the worn parts

OK

Mainshaft and countershaft
thrust play

Continued on the next page

Worn thrust washer, collar,

NG

and/or gear thrust faces

Replace the worn parts

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Bearings (Mainshaft,
countershaft, and individual
gears)

OK

NG

Worn or broken bearings(s)

MANUAL TRANSMISSION 7B1-59

Replace the bearing(s)

Mainshaft splines
Synchronizer clutch hub
splines

OK

Synchronizer assembly

NG

Worn splines

NG

Weak or broken spring

Replace the main shaft and
the synchronizer clutch hub

Replace the spring

7B1-60 MANUAL TRANSMISSION

Checkpoint Trouble Cause Countermeasure

4. OIL LEAKAGE

Oil level

OK

Gear oil

OK

Drain plug and/or filler plug

OK

Gaskets

NG

Oil level too high

NG

NG

Loose plug(s)

NG

Defective or improperly
installed gasket(s)

Drain the oil to the correct
level

Replace the gear oilImproper gear oil

Tighten the plug(s) and
replenish the oil

Replace the gasket(s)

OK

Air breather not installed

Air breather

OK

Front cover oil seal Replace the oil seal

OK

Rear cover oil seal

NG

Air breather clogged

NG

Worn or scratched oil seal

NG

Worn or scratched oil seal

Install the air breather
Replace the air breather

Replace the oil seal

MANUAL TRANSMISSION 7B1-61

ILLUSTRATION

TOOL NO.

TOOL NAME

5-8840-2155-0

Bearing remover

5-8840-2027-0

Special Tools (4

Puller

´´´´

2)

ILLUSTRATION

TOOL NO.

TOOL NAME

5-8840-2159-0

Mainshaft end bearing

installer

5-8840-0015-0

Bearing

remover/installer

5-8840-2160-0

Holding fixture

5-8840-0003-0

Holding fixture base

5-8840-2156-0

Wrench

5-8840-2797-0

Rear case oil seal

installer

5-8840-0026-0

Front cover oil seal

installer

9-8522-1165-0

Mainshaft collar remover

5-8840-0047-0

Tork bit wrench

(T–45)

5-8840-0007-0

Driver handle

7B1-62 MANUAL TRANSMISSION

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.

General Description

MUA Transmission (4´´´´4)

MANUAL TRANSMISSION 7B1-63

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.

A07R300003

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

Disassembled View

Transmission (4

´´´´

4)

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

RTW47BLF 001001

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).

Legend

(1) Knob
(2) Rear Floor Console
(3) Front Floor Console

745R300006

RTW47BM H000101

7B1-66 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.

9. Remove front propeller shaft (7).

NOTE: Apply alignment marks on the flange at both

front and rear sides.

11. Remove the exhaust pipe (9). (6VE1 only)

12. Disconnect harness connectors and clips on the
transfer.

·

Actuator connector

·

Car Speed Sensor

RTW37ASH 000101

10. Loosen the front exhaust pipe fixing nuts (8) at the
engine side but not remove them. (Diesel engine
only)

401RS023

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

810R300069

MANUAL TRANSMISSION 7B1-67

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).

Diesel engine

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

220LV019

17. Support transmission with a transmission jack.

Legend

(1) Bolt

(2) Nut
(3) Fuel Pipe Assembly

6VE1, C24NE

220R300012

220RS0001

18. Remove engine rear mount nuts (14) from
transmission crossmember (15).

Scan-2

7B1-68 MANUAL TRANSMISSION

19. Remove engine rear mount bolts fixing
transmission.

20. Remove the middle part of transmission
crossmember (15) by removing four fixing bolts and
nuts.

220R300009

22. Remove starter (16). (Diesel engine only)

060L100070

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)

21. Take out the rear support rubber.

501R30007

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.

MANUAL TRANSMISSION 7B1-69

NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.

Legend

(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar

220RW019

220RW063

220RW064

24. Remove transmission retaining nuts and bolts(17).
Remove transmission assembly (18) from the

vehicle.

Installation

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.

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

RTW37BLF 000901

6VE1

MANUAL TRANSMISSION 7B1-71

RTW37BLF 0001

7B1-72 MANUAL TRANSMISSION

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.

RTW37BLF 000201

220RS006

MANUAL TRANSMISSION 7B1-73

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 76 Nm (7.7 kgm/56 lbft)

Nut 37 Nm (3.8 kgm/28 lbft)

6VE1, C24NE

12. Connect transmission harness connectors and clips.
Connector: transfer neutral switch, 2W - 4W switch,
backup switch, transmission neutral switch.

Scan-2

Diesel engine

Legend

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

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.

810R300069

7B1-74 MANUAL TRANSMISSION

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)

261R300005

18. Install the exhaust pipe (9). (6VE1)

Torque: 67 Nm (6.8 kgm/49 lbft)

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

RTW37AS H000101



ft)

MANUAL TRANSMISSION 7B1-75

21. Install grommet assembly (4).

Torque: Screw 1.4 Nm (0.14 kgm/12 lbin)

Nut 7 Nm (0.7 kgm/61 lbin)

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.

RTW47BM H000101

7B1-76 MANUAL TRANSMISSION

Major Component

Transmission Case

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

RTW47BLF 000101

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)

Legend

(1) Shift fork pin

(2) Shift fork
(3) Release bearing

RTW47BS H000601

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

RTW37AS H0002

Legend

(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).

7B1-78 MANUAL TRANSMISSION

Rear Oil Seal Replacement

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.

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)

220R300025

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 Nm (2.0 kgm/14 lbft)

261R300004

MANUAL TRANSMISSION 7B1-79

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.

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

RTW37AS H0002

Legend

(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)

7B1-80 MANUAL TRANSMISSION

12. Install the washer and snap pin. (6VE1)

RTW47BM H000201

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.

14. Install the release bearing (5) on the front cover,
joining it to the shift fork.

A07RW075

MANUAL TRANSMISSION 7B1-81

Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and

Interlock Pin

Disassembled View

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

RTW47BLF 000501

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.

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.

220RS011

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.

· Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.

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

MANUAL TRANSMISSION 7B1-83

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 Limit

1st-2nd

3rd-4th

Rev.5th

9.60 - 9.85 mm

(0.378 - 0.388 in)

9.60 - 9.80 mm

(0.378 - 0.386 in)

9.0 mm

(0.354 in)

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)

220RS012

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)

230RS006

SOUTH AFRICA 5th-RV Only
Detent Spring Free Length

Compressed Standard

Outer 20 mm (0.787 in)

Inner 20 mm (0.787 in)

93.5 – 103.3 N

(21.0 – 23.3 lb)

26.4 – 36.3 N
(5.9 – 8.2 lb)

220RS013

7B1-84 MANUAL TRANSMISSION

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.

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)

Legend

(1) Warped

220RS030

230RS007

Disassembled View

Reverse Gear and 5th Gear

MANUAL TRANSMISSION 7B1-85

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

226R300024

7B1-86 MANUAL TRANSMISSION

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.

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).

6. Remove the reverse idler gear assembly (8) from
the intermediate plate (27).

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

262RW079

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).

226RS005

226RS006

10. Remove counter reverse gear (16).

226RS004

MANUAL TRANSMISSION 7B1-87

11. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).

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.

226RS007

226RW210

· Use the mainshaft nut wrench 5-8840-2156-0 to
remove the mainshaft nut (20).

·

Engage the 3rd-4th synchronizer with the 3rd

gear.

·

Engage the 1st-2nd synchronizer with the 1st

gear.

226RW211

226RW212

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).

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.

226RS010

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.

226RS011

220RW137

16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).

226RW212

MANUAL TRANSMISSION 7B1-89

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)

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.

4. Install needle bearing (24), reverse gear (23), and
reverse block ring (22).

220RW137

226RS013

226RS049

7B1-90 MANUAL TRANSMISSION

6. 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 (20) to the specified
torque.

Torque: 137 Nm (14 kgm/101 lbft)

8. Use a punch to stake the mainshaft nut (20).

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.

226RW153

226RW214

226RW151

MANUAL TRANSMISSION 7B1-91

11. Install the counter 5th gear (15) to the counter shaft.

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.

226RS019

·

There are six snap ring sizes available.

The snap rings are color‐coded to indicate
their thickness.

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

226RS021

·

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

226RS020

faces to gear side.

7B1-92 MANUAL TRANSMISSION

14. Select reverse idler gear snap ring (7) which will
provide the minimum clearance between the
intermediate plate (27) and the snap ring (7).

·

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

226RS022

·

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.

·

Select appropriate thrust washer from chart.

·

There are four thrust washer sizes available.

Thrust Washer Availability

Thickness

mm (in)

7.9 (0.311) White

8.0 (0.315) Yellow

8.1 (0.319) Green

8.2 (0.323) Blue

Color

Coding

A mm (in)

8.05 - 8.1

(0.317-0.319)

8.1 - 8.2

(0.319-0.323)

8.2 - 8.3

(0.323-0.327)

8.3 - 8.36

(0.327-0.329)

Clearance

mm (in)

0.15 - 0.25

(0.006-0.010)

0.1 - 0.25

(0.004-0.010)

0.1 - 0.25

(0.004-0.010)

0.1 - 0.21

(0.004-0.008)

226RS023

·

The thrust washers are color coded to indicate

their thickness as shown in the figure.

226RS021

·

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.

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

226L100002

7B1-94 MANUAL TRANSMISSION

Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft

Disassmebled View

226RS026

MANUAL TRANSMISSION 7B1-95

Legend

(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

7B1-96 MANUAL TRANSMISSION

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).

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).

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.

Legend

226RW216

(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).

226RW217

226RS008

226RW218

MANUAL TRANSMISSION 7B1-97

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).

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.

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

16. Remove center roller bearing (29) from counter gear
shaft (30).

226RW219

Legend

(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

226RW220

7B1-98 MANUAL TRANSMISSION

Inspection and Repair

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.

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)

226RS035