tfmua-we-1211th 1st wsmw 120 tf tis 12tf transmission

8/11/2019 Tfmua-we-1211th 1st Wsmw 120 Tf Tis 12tf Transmission

1/129

WORKSHOP MANUAL

TRANSMISSION

(MUA model)

2012MY


2/129

This Workshop Manual deals only with the screen toned section(s) in the table below.

Section Sub Section

0 GENERAL INFORMATION 0 Introduction

14A Service Information Guide

14B Vehicle Information

1 ENGINE 15B Maintenance Information

15C Functional Inspection

15D Symptom15E DTC Information

1A Engine Control

1B Mechanical

1C Fuel System

1D Cooling

1E Lubrication

1F Induction

1G Exhaust

1H Aux. Emission Control Devices

1I Speed Control Systems

1J Electrical2 SUSPENSION 16B Maintenance Information


16D Symptom

2B Front Suspension

2C Rear Suspension

2D Wheel, Tire System

3 DRIVELINE, AXLE 17B Maintenance Information


17D Symptom

17E DTC Information

3A Driveline Control3B Differentials

3C Drive Shaft System

3D Transfer Case

4 BRAKES 18B Maintenance Information


18D Symptom

18E DTC Information

4A Brake Control

4B Brake System

4C Parking Brake System

4D ABS5 TRANSMISSION, TRANSAXLE 19B Maintenance Information


19D Symptom

19E DTC Information

5A Transmission Control

5B Automatic

5C Manual

5E Clutch System

6 STEERING 20B Maintenance Information


20D Symptom6B Power Assisted System


3/129

Section Sub Section

7 HVAC 21B Maintenance Information


21D Symptom

7B Heater, Ventilator, Airconditioner

8 RESTRAINTS 22B Maintenance Information

22C Functional Inspection22D Symptom

22E DTC Information

8A SRS Control

8B Air Bag Systems

8C Seat Belt Systems

9 BODY, CAB, ACCESSORIES 23B Maintenance Information


23D Symptom

9A Lighting Systems

9B Wiper, Washer Systems

9C Electrical Control, Entertainment9E Instrumentation, Driver Info.

9G Hood, Fenders, Doors

9H Cab Structure

9I Seats

9J Security and Locks

9L Exterior, Interior Trim

9P Unibody Sub-frames

9T Glass, Windows, Mirrors

10 BODY CONTROL 36B Maintenance Information


36D Symptom36E DTC Information

10I Body Control

10 SECURITY AND LOCKS CONTROL 42B Maintenance Information


42E DTC Information

10S Security and Locks Control

11 FRAME 24B Maintenance Information

- ETM - Using the Wiring Diagram

- Power System

- Engine

- Chassis- Brake

- Safety

- Driver Assist

- Accessory

- Light

- Data Communications

- Location Diagram

- Connector List


4/129

Description Transmission, Transaxle

Maintenance Information

(MUA)

Table of Contents

Function, structure, operation of transmission, transaxle

.......................................................................................19B-2

Primary specifications of transmission, transaxle.........19B-8

Maintenance Information (MUA) 19B-1


5/129

Function, structure, operation of transmission, transaxle

1. Function, structure, operation of transmission,

transaxle

Note

Cross-sectional drawing of MUA5H

transmission (4 x 2 model)

Note

Cross-sectional drawing of MUA5H

transmission (4 x 4 model)

19B-2 Maintenance Information (MUA)


6/129

MUA5H transmission is a constant mesh type

transmission and synchronized at all speeds. This

transmission is designed to achieve lower operating force

and quietness.

Main components of this transmission consist of a

transmission case integrated with the clutch housing, an

intermediate plate, a rear cover, and the gears, and the

transmission control box is located inside the

transmission.

Note

Cross-sectional drawing of the clutch



7/129

The clutch assembly consists of a clutch pressure plate, a

clutch cover, a diaphragm spring drive pin and a clutch

disc.

The clutch pedal is connected to the release bearing

assembly via the shift fork.

The clutch disc is installed between the flywheel and the

clutch pressure plate.

A push-type clutch is utilized in this transmission.

When the clutch pedal is depressed, the shift fork moves

toward the release bearing assembly.

By the release bearing assembly, diaphragm overcomes

the force of the diaphragm spring and the clutch disc is

released from the flywheel and clutch pressure plate to

disengage the clutch.

Note

Cross-sectional drawing of the master cylinder

The master cylinder converts mechanical energy into oil

pressure energy.

When the clutch pedal is depressed, the push rod moves

toward the piston to close the return port.

The clutch fluid is forced to discharge from the master

cylinder.

When the clutch pedal is released, the return spring

returns the piston to its original position.

The return port opens and the clutch fluid returns to the

fluid reservoir.

When the clutch pedal is released quickly, the fluid

pressure on the return spring side becomes lower than the

fluid pressure on the push rod side.

As a result, the fluid pressure on the push rod side rapidly

flows into the return spring side through the port within

the piston head.



8/129

Then the pressure on both sides of the piston becomes

equal.

Note

Cross-sectional drawing of the slave cylinder

(4 x 2 model)

Note

Cross-sectional drawing of the slave cylinder

(4 x 4 model)

The slave cylinder converts oil pressure energy into

mechanical energy.

The slave cylinder is moved by the oil pressure supplied

from the master cylinder to operate the shift fork.

The mechanical energy generated by the slave cylinder is

directly proportional to the master cylinder and the slave

cylinder diameters.

An air bleeding screw is provided for air bleeding of the

slave cylinder.

The clutch damper valve slows the clutch fluid returning

speed to reduce the shock torque transmitted to the drive

train when the clutch is rapidly engaged at "Low" or

"Reverse".

Note

Cross-sectional drawing of the oil pressure

damper cylinder



9/129

The oil pressure damper cylinder is installed between the

master cylinder and the slave cylinder to equalize

variations in the clutch pedal feeling.

Note

Cross-sectional drawing of the pressure plate

The pressure plate assembly consists of a pressure plate

with a diaphragm spring.

When the clutch pedal is operated, the pressure plate

moves in an axial direction to engage/disengage with the

clutch.

Note

Cross-sectional drawing of the clutch disc



10/129

The clutch disc consists of a plate and a facing.

The plate consists of a clutch center, a cushioning plate

and a torsion spring.

The facing is secured with rivets to both sides of the

cushioning plate.

The cushioning plate minimizes wear and vibration of the

clutch contact surface, which prolongs the service life.



11/129

Primary specifications of transmission, transaxle

1. Primary specifications of transmission, transaxle Note

Primary specifications of the transmission

Model MUA5H

Transmission type Fully-synchronized forward/reverse gear

Control method Remote control with the gear shift lever on the floor

Gear ratio

1st 4.008

2nd 2.301

3rd 1.427

4th 1.000

5th 0.744

Rev 3.651

Oil level [Reference value] 2.95 L { 0.78 US gal / 0.65 Imp.gal }

Specified oilBESCO GEAR OIL TRANSAXLE

5W-30 or the equivalent

Note

Clutch primary specifications

Item MUA

Clutch type Dry-type single plate (with diaphragm)

Control method Oil pressure

Pressure

plate

Outer diameter 250 mm { 9.84 in }

Inner diameter 160 mm { 6.30 in }

Installing load 6300 N { 642 kg / 1416 lb }

Clutch

disc

Assembly thickness, when free 8.3 mm { 0.327 in }

Assembly thickness, when compressed 7.8 mm { 0.307 in }

Clutch

pedalPlay in the clutch pedal (Reference values) 5.0 to 15.0 mm { 0.2 to 0.6 in }

Master

cylinderInner diameter x stroke

15.87 x 35.00 mm

(0.625 x 1.380)

Slave

cylinderInner diameter x stroke

20.64 x 23.00 mm

(0.813 x 0.906 in)



12/129


Functional Inspection

(MUA)

Table of Contents

Transmission oil inspection...........................................19C-2

Functional Inspection (MUA) 19C-1


13/129

Transmission oil inspection

1. Transmission oil inspection inspection

Note

Inspection of the transmission oil

Remove the filler plug.

Insert your finger into the filler plug hole to check if the

oil is filled up to the lower surface of the hole.

1. Filler plug

2. Drain plug3. Filler plug hole

4. Lower surface of the hole

5. Oil surface

Replenish the oil if the oil level is below the specified

level.

Oil for use

BESCO gear oil transaxle 5W-30 or equivalent

Tighten the filler plug to the specified torque.

Replace the gasket with a new one.

Tightening torque39 Nm { 4.0 kgfm / 29 lbft }

Note

Replacement of the transmission oil

Start the engine and warm up the transmission body

sufficiently.

Stop the engine, remove the drain plug and the filler plug,

and then drain the oil.

When the temperature of the engine is high, be careful so

as not to burn yourself.

Tighten the drain plug to the specified torque.

Replace the gasket with a new one.


From the filler plug hole, fill oil up to the lower surface

of the filler plug hole.Oil for use

BESCO gear oil transaxle 5W-30 or equivalent

Oil capacity [Reference value]

2.95 L { 0.78 US gal / 0.65 Imp.gal }

Tighten the filler plug to the specified torque.


19C-2 Functional Inspection (MUA)


14/129


Symptom

(MUA)

Table of Contents

Abnormal noises from transmission..............................19D-2

Difficulty in shifting......................................................19D-3

Falling out of gears........................................................19D-4

Oil leakage from transmission......................................19D-5

Release failure in the clutch..........................................19D-6

Clutch slipping..............................................................19D-7

Clutch judder.................................................................19D-8

Abnormal noises from the clutch .................................19D-9

Clutch fluid leakage....................................................19D-10

Symptom (MUA) 19D-1


15/129

Abnormal noises from transmission

1. Abnormal noises from transmission diagnostics

Insufficient gear oil or bad gear oil.

Refill or replace.Worn on the flywheel pilot bearing.

Replace.

Worn or damage of the bearing.

Replace.

Worn or damage of the gear.

Replace.

Worn on the spline.

Replace the worn-out part.

Scorching on the gear or bearing thrust.

Replace.Inadequate backlash in the gear engagement.

Replace.

Displacement of the transmission.

Adjust.

19D-2 Symptom (MUA)


16/129

Difficulty in shifting

1. Difficulty in shifting diagnostics

Insufficient gear oil or bad gear oil.

Refill or replace.Failure in clutch pedal play.

Adjust.

Worn or insufficient grease on the sliding section of the

shift lever.

Repair or replace, or apply grease.

Worn on the sliding section of the shift block and shift

rod.


Worn on the groove of the synchronizer sleeve or the

shift arm.


Worn on the thrust washer, collar, or gear thrust surface.


Worn of the synchronizer components.

Replace.

Symptom (MUA) 19D-3


17/129

Falling out of gears

1. Falling out of gears diagnostics

Worn on the shift lever sliding section and excessive

play.Replace the worn-out part.

Deterioration and breakage in the detent ball spring.

Replace.

Worn on the detent ball.

Replace.

Worn on the sliding section of the shift block and shift

rod.


Worn on the groove of the synchronizer sleeve or the

shift arm.


Worn on the thrust washer, collar, or gear thrust surface.


Worn or damage of the bearing.

Replace.

Worn on the spline.


Worn or damage of the synchronizer components.

Replace.

19D-4 Symptom (MUA)


18/129

Oil leakage from transmission

1. Oil leakage from transmission diagnostics

Excessive amount of oil.

Adjust to the proper amount.Bad oil.

Replace oil.

Looseness of the drain plug or filler plug.

Tighten and add oil.

Gasket damage or breakage.

Replace.

Worn or damage on the oil seal.

Replace.

Symptom (MUA) 19D-5


19/129

Release failure in the clutch

1. Release failure in the clutch diagnostics

No play in the clutch pedal.

Adjust.Oil pressure leakage.

Repair.

Deformation of the clutch disc.

Replace.

Sticking of the clutch disc spline.

Apply grease or replace.

Worn or sticking of the input shaft spline.


Deformation of the pressure plate or flywheel.

Repair or replace.Worn on the flywheel pilot bearing.

Replace.

19D-6 Symptom (MUA)


20/129

Clutch slipping

1. Clutch slipping diagnostics

No play in the clutch pedal.

Adjust.Disproportionate worn of the front cover.

Replace.

Worn on the clutch disc facing or adhesion of oil.

Clean or replace.

Front cover oil seal failure.

Replace.

Crankshaft rear oil seal failure.

Replace.

Worn or damage including cracks of the release bearing.

Replace.Weakening of the diaphragm spring or worn on the tip.

Replace.

Symptom (MUA) 19D-7


21/129

Clutch judder

1. Clutch judder diagnostics

Looseness or damage in the engine mounting.

Tighten or replace.Deformation of the pressure plate or flywheel.

Replace.

Deformation of the clutch disc facing.

Replace.

Looseness in the rivet of the clutch disc.

Replace.

Worn on the clutch disc facing or adhesion of oil.

Clean or replace.

Front cover oil seal failure.

Replace.Crankshaft rear oil seal failure.

Replace.

Sticking of the clutch disc spline.


Worn or sticking of the input shaft spline.


19D-8 Symptom (MUA)


22/129

Abnormal noises from the clutch

1. Abnormal noises from the clutch diagnostics

No oil for the clutch pedal shaft.

Repair or replace.No oil for the master cylinder push rod.

Apply grease.

Weakening or damage of the damper spring.

Replace the clutch disc.

Worn on the flywheel pilot bearing.

Replace.

Symptom (MUA) 19D-9


23/129

Clutch fluid leakage

1. Clutch fluid leakage diagnostics

Worn or damage of master cylinder piston cup.

Replace.Worn or damage of slave cylinder piston cup.

Replace.

Improper connection of pipe or hose.

Tighten.

19D-10 Symptom (MUA)


24/129

Transmission, Transaxle

Manual

(MUA)

Table of Contents

Top gear shaft..................................................................5C-2

disassembly.................................................................5C-2

inspection....................................................................5C-3

reassembly..................................................................5C-4

Main shaft........................................................................5C-5

disassembly.................................................................5C-5

inspection....................................................................5C-7reassembly................................................................5C-11

Rear oil seal...................................................................5C-16

removal.....................................................................5C-16

installation.................................................................5C-17

Transmission case..........................................................5C-18

disassembly...............................................................5C-18

reassembly................................................................5C-19

Intermediate plate..........................................................5C-23

disassembly...............................................................5C-23

inspection..................................................................5C-25

reassembly..................................... ...........................5C-27Reverse gearand 5th gear.............................................5C-29

disassembly...............................................................5C-29

inspection..................................................................5C-34

reassembly................................................................5C-37

Counter shaft.................................................................5C-43

disassembly...............................................................5C-43

inspection..................................................................5C-44

reassembly................................................................5C-45

Transmission.................................................................5C-46

removal.....................................................................5C-46

installation.................................................................5C-52

Supplementary Information...........................................5C-60

Manual (MUA) 5C-1


25/129

Top gear shaft

disassembly

1. Needle bearing removal

1. Remove the needle bearing from the top gear shaft.

2. Top block ring removal

1. Remove the top block ring from the top gear shaft.

3. Top gear shaft bearing removal

1. Remove the top gear shaft snap ring from the top

gear shaft using a snap ring pliers.

2. Remove the top gear shaft bearing from the top gear

shaft using special tool.

Note

Use a press and bearing remover/installer.

SST: 5-8840-0015-0 - bearing installer & remover

1. Bearing remover/installer

5C-2 Manual (MUA)


26/129

inspection

1. Top gear shaft bearing inspection

1. Measure the top gear shaft bearing using a dial

gauge.

Note

Measure the play of the top gear shaft bearing.

Replace the top gear shaft bearing if the

measured value exceeds the limit.

Standard0.2 mm { 0.008 in }

Manual (MUA) 5C-3


27/129

reassembly

1. Top gear shaft bearing installation

1. Install the top gear shaft bearing to the top gear shaft.

Note

Install the top gear shaft bearing using a press.

Install the snap ring groove of the top gear

shaft bearing so that it faces the front side of

the transmission.

2. Install the top gear shaft snap ring to the top gear

shaft using a snap ring pliers.2. Top block ring installation

1. Install the top block ring to the top gear shaft.

3. Needle bearing installation

1. Install the needle bearing to the top gear shaft.

Note

Apply grease to the inner and outer

circumferences of the needle bearing, and

install it to the top gear shaft.

5C-4 Manual (MUA)


28/129

Main shaft

disassembly

1. Main shaft snap ring removal

1. Remove the main shaft snap ring from the main shaft

using a snap ring pliers.

2. 3rd - 4th synchronizer assembly removal

1. Remove the 3rd - 4th synchronizer assembly from

the main shaft using special tool.

Note

Use a press and bearing remover/installer.

2. Disassemble the 3rd - 4th synchronizer assembly.



2. Spring

3. Sleeve

4. Clutch hub

5. Insert

3. 3rd block ring removal

1. Remove the 3rd block ring from the main shaft.

4. 3rd gear removal

1. Remove the 3rd gear from the main shaft.

2. Remove the needle bearing from the main shaft.

5. 1st gear removal

1. Remove the 1st gear from the main shaft using

special tool.

Note

Remove the 1st gear, main shaft bearing, 1st

thrust bearing, and needle bearing collar at the

same time by using a press and bearing

remover/installer.


Manual (MUA) 5C-5


29/129


6. 1st block ring removal

1. Remove the ring from the main shaft.

Note

Remove the 1st outside ring and the 1st inside

ring from the 1st block ring.

2. Remove the 1st block ring from the main shaft.


7. 2nd gear removal

1. Remove the snap ring from the main shaft using a

snap ring pliers.

Note

Remove the clutch hub snap ring.

2. Remove the 2nd gear from the main shaft using

special tool.

Note

Remove the 2nd gear, 1st - 2nd synchronizer

assembly, 2nd block ring, 2nd outside ring and

inside ring with a press and bearing remover.

Disassemble the 1st - 2nd synchronizer

assembly.



2. Spring

3. Sleeve

4. Clutch hub

5. Insert


5C-6 Manual (MUA)


30/129

inspection

1. 1st block ring inspection

1. Inspect the 1st block ring.

Note

Replace parts as needed if excessive worn or

damage is discovered during inspection.

2. Measure the 1st block ring using a feeler gauge.

Note

Measure the gap between the block ring and

the dog gear.

Replace the 1st block ring if the measured

value exceeds the limit.


Limit0.8 mm { 0.031 in }

1. Gap

2. 2nd block ring inspection

1. Inspect the 2nd block ring.

Note



2. Measure the 2nd block ring using a feeler gauge.

Note


the dog gear.

Replace the 2nd block ring if the measured



Limit0.8 mm { 0.031 in }

1. Gap

3. 3rd block ring inspection

1. Inspect the 3rd block ring.

Note



2. Measure the 3rd block ring using a feeler gauge.

Note


the dog gear. Replace the 3rd block ring if the measured



Limit0.8 mm { 0.031 in }

4. Top block ring inspection

Manual (MUA) 5C-7


31/129

1. Inspect the top block ring.

Note



2. Measure the top block ring using a feeler gauge.

Note


the dog gear.

Replace the top block ring if the measured



Limit0.8 mm { 0.031 in }

5. Insert inspection

1. Measure the insert using a vernier caliper.

Note


the insert.

Replace the block ring and insert if the


Standard3.86 to 4.16 mm { 0.152 to 0.164 in } 1st -2nd

Limit4.9 mm { 0.193 in } 1st - 2nd

Standard3.46 to 3.76 mm { 0.136 to 0.148 in } 3rd -

4th

Standard4.0 mm { 0.157 in } 3rd - 4th

6. Main shaft inspection

1. Inspect the main shaft.

Note



2. Measure the main shaft using a dial gauge.

Note

Inspect fluctuations in the center of the main

shaft.

Replace the main shaft if the measured value

exceeds the limit.

Limit0.05 mm { 0.0020 in }

7. 1st gear inspection

1. Measure the 1st gear using a dial gauge.

Note

Measure the inner diameter of the gear using

an inside dial gauge.

Replace the 1st gear if the measured value

exceeds the limit.

Standard45.000 to 45.013 mm { 1.7717 to 1.7722 in }

Limit45.100 mm { 1.7756 in }

5C-8 Manual (MUA)


32/129

8. 2nd gear inspection

1. Measure the 2nd gear using a dial gauge.

Note



Replace the 2nd gear if the measured value

exceeds the limit.


Limit52.100 mm { 2.0512 in }

9. 3rd gear inspection

1. Measure the 3rd gear using a dial gauge.

Note



Replace the 3rd gear if the measured value

exceeds the limit.


Limit45.100 mm { 1.7756 in }

10. 1st - 2nd clutch hub inspection

1. Inspect the 1st - 2nd clutch hub.

Note

Set the dial indicator to the 1st - 2nd clutch

hub.

Move the clutch hub left to right as far as

possible.

Replace the 1st - 2nd clutch hub if the



Limit0.2 mm { 0.008 in }

11. 3rd - 4th clutch hub inspection

1. Inspect the 3rd - 4th clutch hub.

Manual (MUA) 5C-9


33/129

Note

Set the dial indicator to the 3rd - 4th clutch

hub.

Move the clutch hub left to right as far as

possible.

Replace the 3rd - 4th clutch hub if the



Limit0.2 mm { 0.008 in }

5C-10 Manual (MUA)


34/129

reassembly

1. 2nd gear installation

1. Apply the engine oil to the 2nd gear.

Note

Apply engine oil to the inner surface of the 2nd

gear and needle bearing thrust surface.

2. Install the needle bearing to the main shaft.

3. Install the 2nd gear to the main shaft.

Note

Install the dog gear to the main shaft in such a

way that it faces the rear side of the

transmission.

4. Apply the engine oil to the ring.

5. Install the ring to the 2nd gear.

Note

Apply engine oil to the inner surface of the

inside ring, outside ring, and block ring.

Install the 2nd inside ring, 2nd outside ring,

and 2nd block ring to the 2nd gear in that

order.

1. 2nd block ring

2. 2nd outside ring

3. 2nd inside ring

4. 2nd gear

5. Needle bearing

2. 1st - 2nd synchronizer assembly reassembly

1. Assemble the 1st - 2nd synchronizer assembly.

Note

Confirm that the clutch hub and sleeve slide

smoothly.

Confirm that the insert is installed to thegroove of the clutch hub ring correctly.

Confirm that the insert spring is installed to the

insert correctly.

Set the insert spring in such a way that the

openings of the spring face the different

directions.

1. Insert

Manual (MUA) 5C-11


35/129

2. Insert spring

3. Sleeve

4. Clutch hub

3. 1st - 2nd synchronizer assembly installation

1. Install the 1st - 2nd synchronizer assembly to themain shaft.

Note

Install in such a way that the one with the

wider boss width faces the 2nd gear.

2. Select the snap ring.

Note

Select the snap ring that creates the minimum

clearance between the clutch hub and the

snap ring.

Note

3 types of snap rings are selectable. A snap ring can be identified with a color code.


Snap ring thickness Identification color

1.80 mm { 0.071 in } Colorless

1.85 mm { 0.073 in } Yellow

1.90 mm { 0.075 in } Blue

3. Install the snap ring to the main shaft using a snap

ring pliers.

Note

Completely insert the snap ring into the snap

ring groove of the main shaft.

4. 1st gear installation

1. Install the ring to the 1st gear.

Note

Install the 1st block ring, 1st outside ring, and

1st inside ring to the 1st - 2nd synchronizer

assembly.

5C-12 Manual (MUA)


36/129

2. Apply the engine oil to the ring.

Note

Apply engine oil to the needle bearing, 1st

gear thrust surface, and ring friction surface.


4. Install the 1st gear to the main shaft.

Note


way that it faces the front side of the

transmission.

1. 1st gear

2. Needle bearing

3. 1st inside ring

4. 1st outside ring

5. 1st block ring

5. Install the thrust bearing to the main shaft.

Note

Install to the main shaft in such a way that the

roller side faces the front side of the

transmission.

5. Color installation

1. Apply the engine oil to the main shaft.

Note

Apply engine oil to the main shaft and main

shaft bearing.

2. Install the main shaft bearing to the main shaft.

Note

Install the main shaft bearing snap ring groove

so that it faces the rear side of the

transmission.

3. Install the color to the main shaft using special tool.

Note

Using a pinion bearing installer and a press,

press the needle bearing collar and the main

shaft bearing gradually.

SST: 9-8522-1165-0 - pinion bearing installer

Manual (MUA) 5C-13


37/129

6. 3rd gear installation

1. Apply the engine oil to the 3rd gear.

Note

Apply engine oil to the 3rd gear and needle

bearing.


3. Install the 3rd gear to the main shaft.

Note


way that it faces the front side of thetransmission.

7. 3rd block ring installation

1. Install the 3rd block ring to the main shaft.

8. 3rd - 4th synchronizer assembly reassembly

1. Assemble the 3rd - 4th synchronizer assembly.

Note


smoothly.

Confirm that the insert is installed to the

groove of the clutch hub ring correctly.


insert correctly.



directions.

1. Insert

2. Insert spring

3. Sleeve

4. Clutch hub

9. 3rd - 4th synchronizer assembly installation

1. Install the 3rd - 4th synchronizer assembly to the

main shaft.

Note


wider boss width faces the 3rd gear.

5C-14 Manual (MUA)


38/129

2. Select the snap ring.

Note


clearance between the 3rd - 4th clutch hub

and the snap ring.

Note

3 types of snap rings are selectable.

A snap ring can be identified with a color code.



1.80 mm { 0.071 in } White

1.85 mm { 0.073 in } Yellow

1.90 mm { 0.075 in } Blue


ring pliers.

Note

Completely insert the snap ring into the snap

ring groove of the main shaft.

Manual (MUA) 5C-15


39/129

Rear oil seal

removal

1. Rear oil seal preparation

Note

The following applies to 2WD.

1. Raise vehicle using the jack.

Note

Use a suitable jack to support the vehicle.

2. Rear propeller shaft assembly removal

Note


1. Remove the center bearing assembly from the frame.

Note

The rear propeller shaft assembly is adjusted

to have a precise balance, so before removing

and disassembling, always place an alignment

mark for each of the joints.

Put the alignment marks on the flange of the

rear propeller shaft.

Remove the fixing bolts of the center bearing.

2. Remove the rear propeller shaft assembly from

vehicle.

3. Rear oil seal removal

Note


1. Remove the rear oil seal from the rear cover.

Note

Use a screwdriver to remove the rear oil seal.

5C-16 Manual (MUA)


40/129


41/129

Transmission case

disassembly

1. Transmission case cleaning

Note

Clean the external portion of the unit with

solvent.

2. Transmission oil drain

1. Drain the transmission oil from the transmission.

3. Release bearing removal

1. Remove the release bearing from the transmission

case.

Note

Remove the release bearing together with thespring as a unit.

4. Shift fork removal

1. Remove the shift fork from the transmission case.

Note

Remove the shift fork and boot.

5. Front cover removal

1. Remove the front cover from the transmission case.

Note

Remove the gasket.

6. Counter front bearing snap ring removal

1. Remove the counter front bearing snap ring from the

counter shaft using a snap ring pliers.

7. Top gear bearing snap ring removal

1. Remove top gear bearing snap ring from the top gear

shaft using a snap ring pliers.

8. Vehicle speed sensor removal

Note

The following applies to 2WD, without ABS.

1. Remove the vehicle speed sensor from the

transmission.

9. Retainer plate removal

Note


1. Remove the retainer plate from the rear cover.

10. Speedometer driven gear removal

Note


1. Remove the speedometer driven gear from the rear

cover.

Note

Remove the speedometer bushing together

with the speedometer driven gear.

When removing the speedometer bushing, put

the alignment marks.

11. Control box removal

1. Remove the control box from the transmission.

Note

Remove the gasket.

12. Rear cover removal

1. Remove the rear cover from the transmission case

and the intermediate plate.

Note

The following applies to 2WD, with ABS.

2. Remove the cap from the rear cover.

13. Intermediate plate removal

1. Remove the intermediate plate from the transmission

case.

Note

Remove the intermediate plate together with

the gear assembly as a unit.

14. Rear oil seal removal

Note


1. Remove the rear oil seal from the rear cover.

2. Dispose of the the rear oil seal.

5C-18 Manual (MUA)


42/129

reassembly

1. Rear oil seal installation

Note


1. Apply the engine oil to the rear oil seal.

Note

Apply engine oil to the outer circumference of

a new oil seal.

2. Apply the grease to the oil seal.

Note

Apply BESCO L2 GREASE or equivalent to

the lip of the oil seal.

3. Install the rear oil seal to the rear cover using special

tool.Note

Use the oil seal installer and grip.

SST: 5-8840-2797-0 - oil seal installer

SST: 5-8840-0007-0 - grip

1. Oil seal installer

2. Grip

3. 2.4 - 3.0 mm0.094 - 0.118 in

2. Intermediate plate installation

1. Install the intermediate plate to the transmissioncase.

Note

Apply ThreeBond 1215 or equivalent to the

aligning surface of the transmission case and

intermediate plate.

Install the intermediate plate together with the

gear assembly as a unit.

Pull the top gear shaft in such a way that the

ball bearing snap ring groove protrudes from

the transmission front case cover installation

surface.Caution

Do not apply any abrupt impact or pressure to

the main shaft.

3. Rear cover installation

1. Install the rear cover to the intermediate plate.

Note

The following applies to 2WD, with ABS.

2. Install the O-ring to the cap.

3. Install the cap to the rear cover.Tightening torque15 Nm { 1.5 kgfm / 11 lbft }

1. Cap

2. O-ring

Manual (MUA) 5C-19


43/129

Note

Apply ThreeBond 1215 or equivalent to the

aligning surface of the intermediate plate and

rear cover.

Protect the shaft spline with a tape so that the

lip section of the rear oil seal is not damaged.

Clean the transmission case bolt hole and the

threaded portion of the bolt.

Dry the transmission case bolt hole and bolt

threaded surface, and then apply LOCTITE

242 or equivalent to the bolt.


1. Rear cover, 15 mm {0.59 in}

2. Intermediate plate, 20 mm {0.79 in}3. Transmission case, 20 mm {0.79 in}

4. Control box installation

1. Install the control box to the transmission case.

Note

Install the control box and a new gasket.

After installing the harness clip and bracket,

tighten the four new bolts to the specified

torque.


5. Speedometer driven gear installation

Note


1. Install the O-ring to the speedometer bushing.

2. Install the speedometer driven gear to the

speedometer bushing.

6. Retainer plate installation

Note


1. Install the speedometer driven gear to the rear cover.

2. Install the retainer plate to the rear cover.


1. Retainer plate

2. Speedometer bushing

3. O-ring

5C-20 Manual (MUA)


44/129

7. Vehicle speed sensor installation

Note


1. Install the vehicle speed sensor to the speedometer

bushing.


8. Top gear bearing snap ring installation

1. Install top gear bearing snap ring to the top gear shaft


Note

Confirm that the snap ring is securely installed.

9. Counter front bearing snap ring installation

1. Install the counter front bearing snap ring to the

counter shaft using a snap ring pliers.Note

Confirm that the snap ring is securely installed.

10. Front cover installation

1. Replace the front oil seal with a new one.

Note

Apply engine oil to the outer circumference of

a new oil seal.

Apply grease to the oil seal lip.

2. Install the front oil seal to the front cover using

special tool.

Note

Firmly fit the front oil seal using the oil seal

installer.

SST: 5-8840-0026-0 - oil seal installer

1. Oil seal installer

3. Install the front cover to the transmission case.

Note

Install a new gasket and the front cover.

Caution

Be careful not to damage the oil seal.

Note

Clean the transmission case bolt hole and dry

it.

Tighten the six new front cover bolts to thespecified torque.


11. Shift fork installation

1. Apply the grease to the shift fork.

Note

Apply EXXON MOBILE RONEX MP grease or

equivalent to the position shown in the

diagram.

Manual (MUA) 5C-21


45/129

1. Back

2. Grease application


2. Install the shift fork to the transmission case.

12. Release bearing installation

1. Apply the grease to the release bearing.

Note

Apply EXXON MOBILE RONEX MP grease or

equivalent to the contact surface with the shift

folk.

Caution

Do not apply grease to the inner surface of the

sleeve.


2. Install the release bearing to the front cover.

Note

After installation, connect it to the shift fork.

5C-22 Manual (MUA)


46/129

Intermediate plate

disassembly

1. Detent spring plate removal

1. Remove the detent spring plate from the intermediate

plate.

Note

Remove the gasket.

2. Remove the detent spring from the intermediate

plate.

3. Remove the detent ball from the intermediate plate

using the magnet.

4. Remove the spring from the inhibitor.

2. Reverse - 5th shift rod removal

Note

Insert the round rod into the opposite side of

the shift rod and fix the shift rod.

1. Remove the spring pin from the reverse - 5th shift

rod using a spring pin remover.

Note

Tap out the spring pin.

2. Remove the reverse - 5th shift rod from the

intermediate plate.

Note

The interlock pin locates between the shift

rods in the intermediate plate.

Caution

When removing the shift rod, be careful not to

lose the interlock pin.

3. Reverse - 5th shift arm removal

1. Remove the reverse - 5th shift arm from the 5th

synchronizer assembly.

Note Remove the reverse - 5th shift arm and the

reverse inhibitor.

4. 3rd - 4th shift rod removal

Note



1. Remove the spring pin from the 3rd - 4th shift rod

using a spring pin remover.

Note


2. Remove the 3rd - 4th shift rod from the intermediateplate.

Manual (MUA) 5C-23


47/129

Note



Caution

When removing the shift rod, be careful not tolose the interlock pin.

5. 3rd - 4th shift arm removal

1. Remove the 3rd - 4th shift arm from the 3rd - 4th


6. 1st - 2nd shift rod removal

Note



1. Remove the spring pin from the 1st - 2nd shift rod

using a spring pin remover.

Note


2. Remove the 1st - 2nd shift rod from the intermediate

plate.

Note



Caution

When removing the shift rod, be careful not to


7. 1st - 2nd shift arm removal

1. Remove the 1st - 2nd shift arm from the 1st - 2nd


8. Interlock pin removal

1. Remove the interlock pin from the intermediateplate.

5C-24 Manual (MUA)


48/129

inspection

1. 1st - 2nd shift arm inspection

1. Inspect the 1st - 2nd shift arm.

Note



2. Measure the 1st - 2nd shift arm using the

micrometer.

Note

Measure the thickness of the tip of the shift

arm.

Replace the 1st - 2nd shift arm if the measured



Limit9.0 mm { 0.354 in }

2. 3rd - 4th shift arm inspection

1. Inspect the 3rd - 4th shift arm.

Note

Replace parts as needed if excessive worn ordamage is discovered during inspection.

2. Measure the 3rd - 4th shift arm using the

micrometer.

Note


arm.

Replace the 3rd - 4th shift arm if the measured



Limit

9.0 mm { 0.354 in }

3. Reverse - 5th shift arm inspection

1. Inspect the reverse - 5th shift arm.

Note



2. Measure the reverse - 5th shift arm using the

micrometer.

Note


arm.

Replace the reverse - 5th shift arm if the



Limit9.0 mm { 0.354 in }

4. Detent spring inspection

1. Inspect the detent spring.

Manual (MUA) 5C-25


49/129

Note



2. Measure free length using a vernier caliper.

Note

Replace the detent spring if the measured



Limit26.2 mm { 1.03 in }

3. Measure tension using the spring tester.Note

Replace the detent spring if the measured


Compressed height20 mm { 0.787 in }

Limit87.2 to 97.1 N { 19.6 to 21.8 lb }

5C-26 Manual (MUA)


50/129

reassembly

1. Reverse - 5th shift arm installation

1. Install the reverse - 5th shift arm to the 5th


Note

Apply oil to the inner surface of the inhibitor.

Install the reverse - 5th shift arm and the

inhibitor.

2. Reverse - 5th shift rod installation

1. Install the reverse - 5th shift rod to the intermediate

plate.

Note

Hold the bottom surface of the shift rod using

round rod not to damage the shift rod.

Install a new spring pin.

Caution

Do not reuse the spring pin.

2. Install the interlock pin to the intermediate plate.

Note

Hold the interlock pin so that it does not fall

from the intermediate plate.

3. 1st - 2nd shift arm installation

1. Install the 1st - 2nd shift arm to the gear assembly.

4. 3rd - 4th shift arm installation

1. Install the 3rd - 4th shift arm to the gear assembly.

5. 3rd - 4th shift rod installation


Caution

When installing the shift rod, be careful not to


2. Install the 3rd - 4th shift rod to the intermediate

plate.

Note




Caution


6. 1st - 2nd shift rod installation


Caution

When installing the shift rod, be careful not to


2. Install the 1st - 2nd shift rod to the intermediate

plate.

Note




Caution


7. Detent spring plate installation

1. Install the spring to the inhibitor.

2. Install the detent ball to the intermediate plate.

Note

In installation, apply transmission oil to the

detent ball.

3. Install the detent spring to the intermediate plate.

4. Install the detent spring plate to the intermediate

plate.

Note

Install a new gasket and detent spring plate.

Tighten the two new bolts to the specified

torque.


Manual (MUA) 5C-27


51/129

1. Skew

5C-28 Manual (MUA)


52/129


53/129

2. Remove the speedometer drive gear from the main

shaft.

3. Remove the retainer snap ring from the main shaft.

4. Retainer removal

1. Remove the retainer from the main shaft.

Note


Remove the oil seal collar at the same time.

5. Thrust plate removal

1. Remove the thrust plate from the main shaft.

2. Remove the thrust washer from the main shaft.

Note

Remove the lock ball and the thrust washer.

6. Reverse idle gear removal

1. Remove the snap ring from the idle shaft using a

snap ring pliers.

2. Remove the reverse idle gear from the intermediate

plate.

Note

Remove the idle shaft pin from the reverse idle

shaft and remove the thrust washer and the

reverse idle gear.

7. Counter bearing snap ring removal

1. Remove the counter bearing snap ring from the

counter shaft using a snap ring pliers.

8. Counter 5th gear removal

1. Remove the counter 5th gear from the counter shaft

using a puller.

Note

Remove the counter 5th gear and the bearing

from the counter shaft.

SST: 5-8840-2027-0 - universal puller

5C-30 Manual (MUA)


54/129

9. Counter reverse gear removal

1. Remove the counter reverse gear from the counter

shaft.

10. 5th gear removal

1. Remove the 5th gear from the main shaft.

11. 5th block ring removal

1. Remove the 5th block ring from the main shaft.

12. Needle bearing removal


Note

Remove the two-piece type needle bearings.

13. Main shaft removal

1. Remove the main shaft from the intermediate plate

using special tool.

Note

Install the main shaft and the counter gear to

the holding fixture.

Install the holding fixture to the base.

SST: 5-8840-2160-0 - holding fixture

SST: 5-8840-0003-0 - base

1. Holding fixture

2. Base

Note

Connect the 3rd - 4th synchronizer assembly

and the 3rd gear.

Connect the 1st - 2nd synchronizer assembly

and the 1st gear.

1. Holding fixture

Manual (MUA) 5C-31


55/129

2. Remove the nut from the main shaft using special

tool.

Note

Remove the main shaft nut from the main shaft

with the main shaft nut wrench.

SST: 5-8840-2156-0 - main shaft nut wrench

1. Main shaft nut wrench

14. Reverse gear removal

1. Remove the reverse gear from the main shaft.

Note

Remove the reverse - 5th synchronizer

assembly, reverse block ring, and reverse gear

at the same time by inserting a driver between

the reverse gear and the bearing plate.

15. Reverse needle bearing removal

1. Remove the reverse needle bearing from the main

shaft.

16. Bearing plate removal

1. Remove the bearing plate from the intermediate plate

using special tool.

Note

Remove the bearing plate by using the TORX

bit wrench.

SST: 5-8840-0047-0 - torx bit wrench

5C-32 Manual (MUA)


56/129

1. TORX bit wrench

17. Snap ring removal

1. Remove the bearing snap ring from the main shaft


Note

Hold the snap ring in a open condition with the

snap ring pliers, and slide the intermediate

plate backward to take out the intermediate

plate and snap ring.

1. Snap ring pliers

2. Snap ring

Manual (MUA) 5C-33


57/129

inspection

1. 5th block ring inspection

1. Inspect the 5th block ring.

Note



2. Measure the 5th block ring using a feeler gauge.

Note


the dog gear.

Replace the 5th block ring if the measured



Limit0.8 mm { 0.031 in }

2. Reverse block ring inspection

1. Inspect the reverse block ring.

Note


damage is discovered during inspection.2. Measure the reverse block ring using a feeler gauge.

Note


the dog gear.

Replace the reverse block ring if the measured



Limit0.8 mm { 0.031 in }

3. Insert inspection

1. Measure the insert using a vernier caliper.

Note

Measure the gap between the insert key and

block ring groove.

Replace the insert key and block ring if the



Limit4.1 mm { 0.161 in }

2. Measure the insert using a feeler gauge.

Note

Measure the gap between the insert key and

clutch hub.

Replace the insert key and clutch hub if the



5C-34 Manual (MUA)


58/129

Limit0.4 mm { 0.016 in }

4. 5th gear inspection

1. Measure the 5th gear using a dial gauge.

Note

Measure the inner diameter of the 5th gear

using an inside dial gauge.

Replace the 5th gear if the measured value

exceeds the limit.


Limit32.100 mm { 1.264 in }

5. Counter reverse gear inspection

1. Measure the reverse gear using a dial gauge.

Note

Measure the inner diameter of the counter

reverse gear using an inside dial gauge.

Replace the counter reverse gear if the



Limit48.100 mm { 1.894 in }

6. Reverse idle gear inspection

1. Measure the idle shaft using the micrometer.

Note

Measure the diameter of the reverse idle shaft.

2. Measure the reverse idle gear using a dial gauge.

Note

Measure the inner diameter of the reverse idle

gear.

3. Calculate the clearance from measured value.

Note

Read the difference between the innerdiameter of the reverse idle gear and the

Manual (MUA) 5C-35


59/129

diameter of the reverse idle shaft and calculate

the clearance between the idle gear and idle

gear shaft.

Replace the idle gear and idle shaft if the



Limit0.150 mm { 0.0059 in }

7. Revers - 5th clutch hub inspection

1. Inspect the reverse - 5th clutch hab.

Note

Set the dial indicator to the reverse 5th clutch

hub.

Move the reverse 5th clutch hub left to right as

far as possible.

Record the reading numerical value from thedial indicator.

Replace the reverse - 5th clutch hub if the



Limit0.3 mm { 0.012 in }

8. Main shaft rear bearing inspection

1. Measure the main shaft rear bearing using a dial

gauge.

Note

Measure the play of the main shaft rear

bearing.

Replace the main shaft rear bearing if the



5C-36 Manual (MUA)


60/129

reassembly

1. Intermediate plate installation

1. Install the intermediate plate to the gear assembly.

Note

Connect the counter gear with the main shaft.

Install the main shaft assembly and the

counter gear to the holding fixture.

Install the holding fixture to the base.

SST: 5-8840-2160-0 - holding fixture

SST: 5-8840-0003-0 - base

1. Holding fixture

2. Base


ring pliers.

2. Bearing plate installation

1. Install the bearing plate to the intermediate plate.

Note

Install a new bolt.

Tighten it to the specified torque using TORX

bit wrench, T-45.


SST: 5-8840-0047-0 - torx bit wrench

1. TORX bit wrench, T-45

3. Reverse needle bearing installation

1. Install the reverse needle bearing to the main shaft.

4. Reverse gear installation

1. Install the reverse gear to the main shaft.

Note

Install the reverse gear and reverse block ring

together to the main shaft.

5. Revers - 5th synchronizer assembly reassembly

1. Assemble the reverse - 5th synchronizer assembly.

Note

Install the clutch hub face so that the one

faces the sleeve groove.


smoothly.

Manual (MUA) 5C-37


61/129

1. Sleeve groove

2. Clutch hub face

Note

Confirm that the insert is installed to the

groove of the clutch hub correctly.


insert correctly.



directions.

1. Insert

2. Insert spring

3. Sleeve

4. Clutch hub

6. Revers - 5th synchronizer assembly installation

1. Install the reverse - 5th synchronizer assembly to the

main shaft.

Note


wider boss width faces the reverse gear.

Engage the 1st - 2nd and 3rd - 4th

synchronizers with the 1st and 3rd gears

respectively to prevent the main shaft fromrotating.

2. Install the mainshaft hub nut to the main shaft using

special tool.

Note

Tighten a new main shaft nut to the specifiedtorque using the main shaft nut wrench.

Tightening torque137 Nm { 14 kgfm / 101 lb

ft }

SST: 5-8840-2156-0 - main shaft nut wrench

5C-38 Manual (MUA)


62/129

1. Main shaft nut wrench

Note

After installation, crimp the main shaft hub nut

using a punch.

7. Needle bearing installation


8. 5th block ring installation

1. Install the 5th block ring to the main shaft.

9. 5th gear installation

1. Install the 5th gear to the main shaft.

10. Counter reverse gear installation

1. Install the counter reverse gear to the counter shaft.

Note

Apply engine oil to the reverse gear andcounter reverse gear.

Install the reverse gear in such a way that the

protruding portion of the reverse gear faces

the intermediate plate.

11. Counter 5th gear installation

1. Install the counter 5th gear to the counter shaft.

12. Counter bearing snap ring installation

1. Install the bearing to the counter shaft.

2. Install the counter bearing snap ring to the counter

shaft using a snap ring pliers.

Note


clearance between the bearing and the snap

ring.

Manual (MUA) 5C-39


63/129

Note


The snap ring can be identified with a color

code and dash code.



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

Note

Completely insert the counter bearing snap

ring into the snap ring groove of the counter

shaft using snap ring pliers.

13. Reverse idle gear installation

1. Install the reverse idle gear to the intermediate plate.

Note

Install the reverse idle shaft, reverse idle gear,

thrust washer, and idle shaft pin to the reverseidle gear assembly.

Install the thrust washer so that the oil groove

faces the gear.

2. Install the snap ring to the idle shaft using a snap

ring pliers.

Note

Select a snap ring that creates the minimum

clearance between the intermediate plate and

the snap ring.

Note


A snap ring can be identified with a color code.

5C-40 Manual (MUA)


64/129



1.2 mm { 0.047 in } White

1.3 mm { 0.051 in } Yellow

1.4 mm { 0.055 in } Blue

Note

Completely insert the counter bearing snap

ring into the snap ring groove of the counter

shaft using snap ring pliers.

14. Thrust washer installation

1. Install the thrust washer to the main shaft.

Note

Measure the clearance between the 5th gear

and the thrust washer with a feeler gauge.


1. Clearance

Note

Select an appropriate thrust washer from the

table.

4 types of thrust washer sizes are selectable.

A thrust washer can be identified with a color

code.

Thrust

washer

thickness

Identificati

on colorWidth A Clearance

7.9 mm

{ 0.311

in }

White

8.05 to

8.10 mm

{ 0.317 to

0.319 in }

0.15 to

0.25 mm

{ 0.006 to

0.010 in }

8.0 mm

{ 0.315

in }

Yellow 8.1 to 8.2

mm { 0.319

to 0.323 in }

0.10 to

0.25 mm

{ 0.004 to

0.010 in }

8.1 mm{ 0.319

in }

Green 8.2 to 8.3

mm { 0.323

to 0.327 in }

0.10 to0.25 mm

{ 0.004 to

0.010 in }

8.2 mm

{ 0.323

in }

Blue

8.30 to

8.36 mm

{ 0.327 to

0.329 in }

0.10 to

0.21 mm

{ 0.004 to

0.008 in }

Note

Apply grease to the thrust washer and the lock

ball and install them to the main shaft.

15. Thrust plate installation

1. Install the thrust plate to the main shaft.

16. Retainer installation

1. Install the retainer to the main shaft.

Note


Install the retainer snap ring to the main shaft.

17. Speedometer drive gear installation

Note


Manual (MUA) 5C-41


65/129

1. Install the speedometer drive gear to the main shaft.

Note

Install the clip.


ring pliers.

18. Main shaft rear bearing installation

1. Apply the engine oil to the main shaft rear bearing.

Note

Apply engine oil to the main shaft rear bearing

outer and inner circumferences.

2. Install the main shaft rear bearing to the main shaft

using special tool.

Note

Use a bearing installer.

SST: 5-8840-2159-0 - bearing installer

1. Bearing installer

Note


3. Apply the engine oil to the oil seal color.

Note

Apply it to the inner circumference of the oil

seal collar.

4. Install the oil seal color to the main shaft usingspecial tool.

Note

Use a bearing installer.

SST: 5-8840-2159-0 - bearing installer

19. Main shaft snap ring installation

1. Install the main shaft snap ring to the main shaft


5C-42 Manual (MUA)


66/129

Counter shaft

disassembly

1. Front taper bearing removal

1. Remove the snap ring from the counter shaft using a

snap ring pliers.

2. Remove the front roller bearing from the counter

shaft using special tool.

Note

Remove the ring, outer race, and bearing

assembly using a press and bearing remover/

installer.

Remove the inner race using a press and

bearing remover/installer.



2. Center roller bearin removal

1. Remove the center roller bearing from the counter

shaft.

Manual (MUA) 5C-43


67/129

inspection

1. Front taper bearing inspection

1. Measure the front roller bearing using a dial gauge.

Note

Measure the play of the front roller bearing.

Replace the front roller bearing if the



2. Center roller bearin inspection

1. Measure the center roller bearing using a dial gauge.

Note

Measure the play of the center roller bearing.

Replace the center roller bearing if the



5C-44 Manual (MUA)


68/129

reassembly

1. Center roller bearin installation

1. Apply the engine oil to the center roller bearing.

Note

Apply it to the outer and inner circumference

portions.

2. Install the center roller bearing to the counter shaft.

Note

Assemble the center roller bearing in the

direction as shown in the diagram.

After installation, confirm that the outer race

moves only in the direction indicated by the

arrow.

2. Front taper bearing installation

1. Install the inner race to the counter shaft using

special tool.

Note

Install the outer race and the roller assembly to

the counter shaft.

Install the ring to the counter shaft using abearing installer.

SST: 5-8840-2194-0 - counter gear bearing installer

1. Ring

2. Outer race and roller assembly

3. Inner race

2. Install the snap ring to the counter shaft using a snap

ring pliers.

Manual (MUA) 5C-45


69/129

Transmission

removal

1. Battery ground cable disconnect

1. Disconnect the battery ground cable from the battery.

Note


Caution

Before removing the transfer assembly from

the vehicle, change the transfer mode to 2WD

using the 2-4 switch.

2. Shift lever knob removal

1. Remove the shift lever knob from the shift lever.

3. Console box removal

Note

Below is for the center console type.

1. Remove the shift console cover from the console

box.

Note

Disconnect the cigarette lighter connector.

Below is for the 2WD center console type.

2. Remove the cover from the console box.

Note Below is for the center console type.

3. Remove the console box from the floor.

Note

Remove the 3 clips.

Open the console box cover and remove 2

screws.

Remove the control box backward.

Below except for the center console type.

4. Remove the console cover from the instrument

panel.

Note

Remove the 2 clips.

Disconnect the cigarette lighter connector.

5. Remove the cup holder cover from the floor.

6. Remove the bracket from the floor.

4. Grommet assembly removal

Note

With floor console lid

1. Remove the insulator from the shift lever.

2. Remove the grommet assembly from the floor panel.

1. Insulator

2. Grommet assembly

3. Floor panel

Note

Without floor console lid

3. Remove the grommet assembly from the floor panel.

4. Remove the insulator from the shift lever.

1. Grommet assembly

2. Insulator

3. Floor panel

4. Shift lever dust cover

5. Shift lever removal

1. Remove the shift lever from the transmission.

5C-46 Manual (MUA)


70/129

6. Engine hood assembly removal

1. Open the engine hood.

Note

Support the engine hood.

2. Remove the hinge bolt from the engine hood.

Note

Before removing the hinge from the engine

hood, put a marking of the hinge location for

putting the hinge back in place.

7. Engine cover removal1. Remove the engine cover from the engine.

1. Engine cover

8. Washer hose disconnect

1. Disconnect the washer hose from the joint.

9. Wiper arm removal

1. Remove the wiper arm from vehicle.

Note

Remove the nut to remove the wiper arm and

the blade.

1. Wiper arm cover

2. Nut

3. Wiper arm, blade

10. Side cowl cover removal

1. Remove the side cowl cover from the body.

11. Cowl cover removal1. Remove the cowl cover from the body.

12. Wiper linkage removal

1. Remove the wiper linkage from vehicle.

Note

Remove the bolt and nut from the wiper

linkage.

Remove the connector from the wiper motor.

Manual (MUA) 5C-47


71/129

1. Nut

2. Bolt

Note

Remove together with the wiper motor.

13. Cowl panel removal

1. Disconnect the washer hose from the joint.

2. Remove the cowl panel from vehicle.

14. Transmission preparation

1. Raise vehicle using the jack.

Note

Use a suitable stand to support the vehicle.

15. Rear propeller shaft assembly removal

Refer to "3.Driveline, Axle 3C.Drive Shaft System(All

models) Rear propeller shaft assembly removal".

16. Front propeller shaft assembly removal

Note


1. Remove the front propeller shaft assembly from

vehicle.

Note

Remove the exhaust and the transfer

protector.

Put the alignment marks on the flanges on

both the front and rear sides of the front

propeller shaft.

Note

Remove the bolt, nut and washer on the front

axle.

Remove the bolt, nut and washer on the

transfer.

Remove the front propeller shaft assembly.

17. Engine harness disconnect

Note


1. Disconnect the engine harness from the connector.

Note

Disconnect the neutral switch, backup light

switch, and vehicle speed sensor.


Disconnect the transmission side neutral

switch, backup switch, actuator, 2-4 switch,

transfer side neutral switch, and vehicle speed

sensor.

5C-48 Manual (MUA)


72/129

1. Transmission side neutral switch connector,

backup switch connector

2. Vehicle speed sensor connector, without ABS

3. Actuator connector

4. 2-4 switch connector

5. Transfer side neutral switch connector

18. Catalyst converter removal

Refer to "1.Engine 1G.Exhaust(4JJ1) Catalyst

converter removal".

Refer to "1.Engine 1G.Exhaust(4JK1) Catalyst

converter removal".19. Clutch slave cylinder removal

1. Remove the clutch slave cylinder from the

transmission.

20. Transmission crossmember removal

1. Install the rear engine hanger to the cylinder head.

Note

The following applies to the high-output

specifications.

SST: 5-8840-2861-0 - engine hanger

Note

The following applies to the standard output

specifications.

SST: 5-8840-2886-0 - rear engine hanger

Tightening torque25 Nm { 2.5 kgfm }

1. Rear engine hanger

2. Install the wire to the engine hanger and the hoist.

Note

Hold up the engine as high as not to be lifted

up.

3. Hold the transmission using the jack.

Note

Support the transmission with a transmission

jack.

Manual (MUA) 5C-49


73/129

4. Remove the transmission crossmember from the

frame.

Note

Remove the nut fixed on the transmission

cross member.


Remove the nut fixed on the transmission.

1. Transmission

2. Transmission rear section installation nut

3. Cushion rubber

4. Cross member rear section installation nut

5. Transmission cross member

Note


Remove the bolt fixed on the transmission.

Note

Remove the 4 fixing bolts and nuts, and then

remove the middle parts of the transmission

cross member.


Note


5C-50 Manual (MUA)


74/129

Note

Remove the cushion rubber.

21. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ1) Starter

motor removal".

Refer to "1.Engine 1J.Electrical(4JK1) Starter

motor removal".

22. Transmission removal

1. Remove the transmission from the engine.

Note


Remove the transmission and engine

tightening bolts.


Remove the transmission and transfer.

23. Transfer assembly removal

Note


1. Remove the transfer assembly from the transmission.

Manual (MUA) 5C-51


75/129

installation

1. Transfer assembly installation

Note


1. Apply the grease to the input shaft.

Note

Apply BESCO L-2 grease or equivalent to the

spline section.

2. Install the transfer assembly to the transmission.


5C-52 Manual (MUA)


76/129

1. 20 mm {0.79 in}

2. 9 mm {0.35 in}

3. 11 mm {0.43 in}

4. 35 mm {0.38 in}

5. 15 mm {0.59 in}

6. 20 mm {0.79 in}

7. 16.5 mm {0.65 in}

8. 15 mm {0.59 in}

9. 43.5 mm {1.71 in}

10. 14 mm {0.55 in}

2. Transmission installation

1. Apply the grease to the top gear shaft.

Note

Apply NICHIMOLY TC-5 or equivalent to the

spline section of the top gear shaft.

2. Install the transmission to the engine.

Note

Slowly operate the transmission jack so that

the front of transmission aligns with the rear ofthe engine.

Slowly operate the transmission jack so that

the transmission becomes parallel to the

engine.

Align the top gear shaft spline section and the

clutch-driven plate spline section.

Tighten the transmission installation nut and

bolt as illustrated in the diagram.


M12

Tightening torque40 Nm { 4.1 kgfm / 30 lbft }M10

Manual (MUA) 5C-53


77/129

1. 40 mm {1.6 in}

2. 32 mm {1.3 in}

3. 60 mm {2.4 in}

4. 90 mm {3.5 in}

5. 75.5 mm {2.97 in}

6. 17 mm {0.7 in}7. 5.5 mm {0.22 in}

8. 20 mm {0.8 in}

9. 10 mm {0.4 in}

10. 1.2 mm {0.05 in}

11. 3.7 mm {0.15 in}

12. 25.5 mm {1.00 in}

13. 51 mm {2.0 in}

14. 12 mm {0.5 in}

15. 11 mm {0.4 in}

16. 18 mm {0.7 in}

17. 26 mm {1.0 in}

18. 40 mm {1.6 in}19. 22 mm {0.9 in}

20. 4.5 mm {0.18 in}

21. 30 mm {1.2 in}

22. 14 mm {0.6 in}

3. Starter motor installation

Refer to "1.Engine 1J.Electrical(4JJ1) Starter

motor installation".

Refer to "1.Engine 1J.Electrical(4JK1) Starter

motor installation".

4. Transmission crossmember installation

1. Install the cushion rubber to the transmission.


2. Install the transmission crossmember to the frame.

5C-54 Manual (MUA)


78/129

Note

Install the middle parts of the transmission

cross member.


Note

Install the engine rear mounting nut to the

transmission cross member.

Tightening torque140 Nm { 14.3 kgfm / 103 lb

ft }

Note

Remove the transmission jack from the

transmission.

3. Remove the wire from the engine hanger and the

hoist.

4. Remove the rear engine hanger from the cylinderhead.

1. Rear engine hanger

5. Catalyst converter installation

Refer to "1.Engine 1G.Exhaust(4JJ1) Catalyst

converter installation".Refer to "1.Engine 1G.Exhaust(4JK1) Catalyst

converter installation".

6. Clutch slave cylinder installation

1. Install the clutch slave cylinder to the transmission.

Note

Apply grease to the shift fork hole portion.


7. Engine harness connect

1. Connect the engine harness to the connector.

Note


Connect the vehicle speed sensor, backup

light switch, and neutral switch.


Connect the transmission side neutral switch,

backup switch, actuator, 2-4 switch, transfer

side neutral switch, and vehicle speed sensor.

1. Transmission side neutral switch connector,

backup switch connector

2. Vehicle speed sensor connector, without ABS

3. Actuator connector

4. 2-4 switch connector

5. Transfer side neutral switch connector

8. Rear propeller shaft assembly installation

Refer to "3.Driveline, Axle 3C.Drive Shaft System(All

models) Rear propeller shaft assembly installation".

9. Front propeller shaft assembly installation

Note


1. Install the front propeller shaft assembly to theflange.

Note

Align the alignment marks of each joint that

were made during removal to install.

Caution

Never install the shaft assembly in the reverse

direction.

Clean the installation surface of the flange

yoke and coupling driver to keep the surface

free of foreign matter such as black paint,

grease, and oil.

Manual (MUA) 5C-55


79/129

Note

Tighten the bolt, nut and washer on the

transfer side.


Note

Tighten the bolt, nut and washer on the front

axle.


Note

After installing the propeller shaft, be sure to

apply black paint to the whole exposed area

except for the flange coupling mating surface.

1. Flange coupling exposed area

Note

Install the exhaust and the transfer protector.

10. Cowl panel installation

1. Install the cowl panel to vehicle.

2. Connect the washer hose to the joint.

11. Wiper linkage installation

1. Install the wiper linkage to vehicle.

Note

Install it together with the wiper motor.

1. Nut

2. Bolt

Tightening torque5.3 Nm { 0.5 kgfm / 47 lbin }

Note

Connect the connector to the wiper motor.

12. Cowl cover installation

1. Install the cowl cover to the body.

13. Side cowl cover installation

1. Install the side cowl cover to the body.14. Wiper arm installation

5C-56 Manual (MUA)


80/129

1. Install the wiper arm to vehicle.

Caution

Confirm that the wiper motor is stopped

at the auto stop position.

1. 29 mm (1.14 in)

2. 36.5 - 51.5 mm (1.44 - 2.03 in)

3. 18 mm (0.71 in)

Tightening torque31.0 Nm { 3.2 kgfm / 22.9 lb

ft }

15. Washer hose connect

1. Connect the washer hose to the joint.

16. Engine cover installation

1. Install the engine cover to the engine.

1. Engine cover

17. Engine hood assembly installation

1. Temporarily tighten the hinge bolt to the engine

hood assembly.

Note

Align the hinge with the marking made during

removal.

2. Inspect the clearance.

Note

Check the engine hood assembly and the

fender.

3. Adjust the clearance to a standard value.

Note

Adjust the installation of the engine hood hinge

to adjust the clearance.

1. Clearance: 4.0 mm {0.16 in}

2. Height, level difference: -1.5 mm {-0.06 in}

Note

Turn the hood rest to adjust its height, and

adjust the level di

tfmua-we-1211th 1st wsmw 120 tf tis 12tf transmission

Documents