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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


Disassembly ................................................................................................................ 7B1 24

Inspection and Repair................................................................................................. 7B1 25

Reassembly ................................................................................................................. 7B1 26

Reverse Gear and 5th Gear ............................................................................................ 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


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


Disassembly ................................................................................................................ 7B183Inspection and Repair................................................................................................. 7B183

Reassembly ................................................................................................................. 7B184

Reverse Gear and 5th Gear ............................................................................................ 7B185


Disassembly ................................................................................................................ 7B186

Inspection and Repair................................................................................................. 7B188

Reassembly ................................................................................................................. 7B188

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


8. Install the middle part of transmission crossmember

(12) and bolts.

Tighten the nuts to the specified torque.


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.


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


(2) Nut


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)


150R300003

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MANUAL TRANSMISSION 7B1-1714. Install the exhaust pipe (8). (6VE1)


RTW37ASH000101

15. Install rear propeller shaft (6).


16. Install center bearing on crossemember.


17. Install gear control lever (5).


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.


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).


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MANUAL TRANSMISSION 7B1-217. Install the speedometer sensor (2).


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.


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)



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.


Standard Limit

26.8 mm (1.06 in) 26.2 mm (1.03 in)

SOUTH AFRICA 5th-Rev Only


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.


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).


plate and gear assembly (12).

Install the 3rd-4th shift rod (8) in the intermediate

plate (12).


intermediate plate.

Install the interlock pin (11) and then 1st-2nd

shift rod (7) in the intermediate plate (12).


intermediate plate.





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.


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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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).


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.


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.


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&dash;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


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)


Thickness Color Coding1.2 mm (0.047 in) White


1.4 mm (0.055 in) Blue

226RS021


ring to the reverse idler shaft.


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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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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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)


between the block ring and the dog teeth.

226RS036


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


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


between the clutch hub and the insert.

226RS038


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


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.


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:


clutch hub (5) insert grooves.




slide smoothly.

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266RS049


mainshaft (26).


facing the 2nd gear side.

226RS048

8. Install clutch hub snap ring(19) by performing the

following steps:


minimum clearance between the 1st-2nd clutch

hub and the snap ring.

226RS050


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)



1.80 mm (0.071 in) White


1.90 mm (0.075 in) Blue


ring (19) to the mainshaft (26).


mainshaft snap ring groove.

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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


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


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.


slide smoothly.

4. Install the synchronizer assembly to the

mainshaft.


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


The snap rings are color coded to indicate their

thickness as shown in the figure.

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226RS021

Clutch Hub and Snap Ring Clearance

Standard: 0 - 0.1 mm (0 - 0.004 in)



1.80 mm (0.071 in) White


1.90 mm (0.075 in) Blue


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


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


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


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


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


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


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


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.


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


(2) Nut


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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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.


7. Install the rear support rubber on the transmission

and tighten the bolts to the specified torque.


8. Install the middle part of transmission crossmember

(15) and bolts.

Tighten the nuts to the specified torque.


9. Install engine rear mount nuts (14).


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.


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


(2) Nut


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.


261R300005

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


RTW37ASH000101

19. Install front propeller shaft (7).

Refer to the section Front Propeller Shaft.

20. Install rear propeller shaft (6).


21. Install the center bearing on crossmember.


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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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)


8. Remove the front cover (8) and gasket from the

transmission case.

9. Remove snap ring (7) fixing counter front bearing.


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.


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.


261R300004

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MANUAL TRANSMISSION 7B1-795. Install top gear bearing snap ring (9) and counter

front bearing snap ring (7).


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)



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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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).






plate (12).


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).


plate and gear assembly (12).

Install the 3rd-4th shift rod (8) in the intermediate

plate (12).


intermediate plate.

Install the interlock pin (11) and then 1st-2nd

shift rod (7) in the intermediate plate (12).


intermediate plate.





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.


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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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).


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


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.

220RW137

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

bearing snap ring (2) (26).

226RS011

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.

226RW212

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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.


220RW137

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.


clutch hub (5) ring insert grooves.




slide smoothly.


mainshaft.


facing the reverse gear side.

226RS013

226RS049

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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).

226RS015

This will prevent the mainshaft from turning.

7. Install the new mainshaft hub nut.


tighten the mainshaft nut (20) to the specified

torque.

Torque: 137 Nm (14 kgm/101 lbft)

226RW214

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

226RW153

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.

226RW151

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MANUAL TRANSMISSION 7B1-9111. Install the counter 5th gear (15) to the counter shaft.

226RS019

12. Install ball bearing (14) and bearing snap ring (13)

by performing the following steps:


minimum cl

07_tfmua-we-0431

Documents

manual transmission

disassembled view

gear assembly

reverse gear

main gear shaft

counter gear shaft

transmission case

shift arm